Automated wall finishing system and method

ABSTRACT

A method of generating a building assembly that includes spraying a coating material onto a plurality of pieces of substrate disposed on a first assembly face. The spraying includes spraying the coating material onto the plurality of pieces of substrate via a sprayer configured to apply the coating material to a target surface via a nozzle coupled with a mobile storage container storing the coating material, the coating material impregnating voids of the substrate. The method also includes allowing the coating material impregnating the voids to dry and harden and become rigid to generate the building assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is continuation of U.S. application Ser. No.16/740,848, filed Jan. 13, 2020, which is a continuation of U.S.application Ser. No. 16/141,791, filed Sep. 25, 2018, which is anon-provisional of, and claims the benefit of U.S. ProvisionalApplication No. 62/562,981, filed Sep. 25, 2017, which applications arehereby incorporated herein by reference in its entirety and for allpurposes.

This application is also related to U.S. Non-provisional applicationsfiled contemporaneously herewith having attorney Docket Numbers0111061-001US0, 0111061-002US0, 0111061-003US0, 0111061-004US0,0111061-005US0, 0111061-006US0, 0111061-007US0, having respectiveapplication numbers 15/942,158, 15/942,193, 15/941,886, 15/942,318,15/942,087, 15/942,286 and 15/941,974 and respectively entitled“AUTOMATED DRYWALL PLANNING SYSTEM AND METHOD,” “AUTOMATED DRYWALLCUTTING AND HANGING SYSTEM AND METHOD,” “AUTOMATED DRYWALL MUDDINGSYSTEM AND METHOD,” “AUTOMATED DRYWALL SANDING SYSTEM AND METHOD,”“AUTOMATED DRYWALL PAINTING SYSTEM AND METHOD,” “AUTOMATED DRYWALLINGSYSTEM AND METHOD,” and “AUTOMATED INSULATION APPLICATION SYSTEM ANDMETHOD.” These applications are hereby incorporated herein by referencein their entirety and for all purposes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary perspective drawing illustrating an embodiment ofan automated surface installation and finishing system.

FIG. 2 is an exemplary perspective drawing illustrating anotherembodiment of an automated wall finishing system.

FIG. 3 is an exemplary block diagram illustrating systems of anautomated wall finishing system in accordance with one embodiment.

FIG. 4 is an exemplary block diagram illustrating systems of anautomated wall finishing system in accordance with one embodiment,including a plurality of end effectors configured to couple to an end ofa robotic arm.

FIG. 5 illustrates a block diagram of method of installing surfaces inaccordance with one embodiment.

FIGS. 6a and 6b illustrate example embodiments of a substrate inaccordance with various embodiments.

FIGS. 7a and 7b illustrate an embodiment of an automated compoundapplication process where the joint compound is applied in a thick layerusing a sprayer.

FIGS. 8a, 8b and 9a and 9b illustrate a series of steps in an examplemethod of installing a substrate to generate a wall assembly.

FIG. 10 illustrates an embodiment of a wall finishing system applying acoating to a substrate in accordance with one embodiment.

FIG. 11 illustrates an embodiment of a coating end effector configuredto automatically dispense and apply joint tape at seams betweensubstrate edges.

FIG. 12 illustrates one embodiment of a coating end effector thatincludes a spray gun that is coupled onto the robotic arm.

FIG. 13 illustrates another embodiment of a coating end effector thatincludes a spray gun that is coupled onto the robotic arm.

FIG. 14 illustrates an example of an in-line nozzle for mixingcomponents of the coating, water, and any additives at an applicationsite.

FIG. 15 illustrates an example embodiment of a coating end effector thatincludes a spray pattern detection mechanism, in which a vision systemcan be used to monitor the pattern of coating spray coming out of thenozzle to detect clogs, nozzle wear, low pressure, or other problemswith the spray gun or related system such as coating lines, coatingsource or the like.

FIG. 16 illustrates an example embodiment of a coating end effector thatcomprises a vacuum system that includes a vacuum hood disposed around anend and nozzle of a spray gun to capture overspray.

FIG. 17 illustrates an example embodiment of a coating end effector thatcomprises a spray guard that partially extends about and past the faceof the nozzle of the spray gun.

FIG. 18 illustrates an example of a coating end effector that comprisesa coating flat box to apply the coating compound.

FIG. 19 illustrates an example embodiment of a coating end effector thatcomprises a first blower and a second blower.

FIG. 20 illustrates an example embodiment of a coating end effector,which comprises a nozzle cassette system where a cassette of nozzles isattached to the end of the spray gun.

FIG. 21 illustrates another example embodiment of a coating end effectorthat comprises a nozzle rotating system that can be part of a spray gun.

FIG. 22 illustrates an example embodiment of a substrate applicator endeffector, wherein a roll of substrate is mounted within a roll body ofthe end effector and fed under a roller.

FIG. 23 illustrates an example embodiment of an automated wall finishingsystem where a substrate end effector utilizes studs of a wall assemblyas a guide for delivering substrate between or on the studs, headerand/or footer of a wall assembly.

FIG. 24 illustrates another example embodiment of a coating end effectorthat comprises a fluid stream nozzle and coating nozzle that can be partof a spray gun.

It should be noted that the figures are not drawn to scale and thatelements of similar structures or functions are generally represented bylike reference numerals for illustrative purposes throughout thefigures. It also should be noted that the figures are only intended tofacilitate the description of the preferred embodiments. The figures donot illustrate every aspect of the described embodiments and do notlimit the scope of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following disclosure pertains to an automated drywalling finishingsystem, which in some embodiments can be used for generating a wall,finishing a wall, or the like. Further examples can be used fordrywalling, including one or more of planning a configuration andlocation of drywall pieces on a wall assembly, cutting drywall pieces,hanging drywall pieces, performing mud work on hung drywall pieces,performing sanding on mudded drywall pieces and painting sanded drywallpieces.

Various aspects of the present disclosure pertain to a surface finishingsystem and method for spraying plaster, stucco, parex, gypsum, or thelike, over a porous substrate material to create a wall. In someexamples, the substrate material can comprise mesh, paper, clothsurface, lath, buttonboard, rock lath, rainscreen, drywall board, aporous surface, or the like. The substrate material can be flexible tofollow curved or complex contours in various examples. The material maybe transported in rolls or sheets and fastened to load bearingstructures to generate a portion of a wall. The substrate can alsocomprise a woven structural cabler, woven electrical cables, or thelike. The substrate can be instrumented with sensors that measurehumidity, temperature, conductivity, sound, and the like, which can beused to provide feedback during the spraying process; to serve as inwall-sensors for detection of leaks in the walls, temperature andhumidity of the room, environmental problems; or for other suitablepurposes.

In accordance with a finishing method of one embodiment, a substrate isattached to wood, metal, concrete or any structural material and acoating is sprayed onto the substrate. The coating material can compriseplaster, gypsum, concrete, stucco or other suitable mineral formulation.The coating may also comprise polymers such as latex and acrylics, aswell as adhesion additives including glue and other bonding agents. Thecoating can comprise a synthetic material such as Parex, an acrylicsynthetic stucco, or the like.

One aspect pertains to systems and methods for automated mixing,delivering, applying, curing, and/or drying coatings onto a substrate.In one embodiment, an automated surface finishing system can be used tomix, deliver, apply, and dry coatings onto porous substrates. Theautomated surface finishing system can be used to apply tape on seamsbetween substrate edges, apply coating or plaster onto the tape andsubstrate, expedite the drying process, or any combination of theseprocesses. The automated surface finishing system can also be used toapply the coating and achieve any level of drywall finish includingbetween level 0 and level 5. The automated surface finishing system canutilize joint compound known as mud or setting type compound also knownas hot mud. It can also utilize plaster, gypsum, polymer coatings, orthe like in some example. Joint compound as discussed herein canencompass pre-mixed, topping, taping, multi-use, all-purpose, andsetting type compounds. The automated surface finishing system can alsobe used with other coatings including plaster, cement, stucco, and paintapplied onto drywall, lath, mesh or another suitable substrate. Theautomated surface finishing system can cover how the coating isprepared, how it is delivered onto the substrate and how it is set,cured or dried.

The methods described in this disclosure can be conducted manually orautomatically using an automated system. The automated system cancomprise a robotic manipulator, vision system, tool for cutting asubstrate, tool for attaching the substrate to the structural material,measurement system, mobile cart, coating material pump, poweredfinishing tools, power sprayer and any combination of these components.The robotic arm and mobile base can be driven using pressurized fluids,electric motors, cable drives, belt drives, solenoids, voice coils, orany suitable combination of power source. The automated surfacefinishing system can be electrically or gas powered; it may also utilizepressurized fluid from an external source. The automated system can alsotake the form of a gantry, where a tool is positioned using an x-y-zstage. The tool-holder can have additional degrees of freedom to orienta tool or end effector or change the position of the tool.

The automated systems and methods disclosed can encompasses all or anyof the steps of preparing for, generating and finishing a wall assemblyor other portions of a structure, from planning the layout of thesubstrate material, to attaching the substrate to structural members, tospraying a coating, and finishing the coating. Finishing steps caninclude but are not limited to troweling, sanding, polishing,knocking-down, applying a texture finish, smoothing, compacting,leveling, floating, edging, cutting grooves or expansion gaps, painting,stenciling, and the like. The automated system can be used to controlthe finishing tools allowing for controlled material application,removal, and finishing.

A vision system, measurement sensors, and/or model of a room orstructure can be used to determine how a substrate material should becut to cover the surface. The vision system (which can comprise one ormore camera, LIDAR, radar, sonar, or the like), can be used to create amodel of the structural material including studs and determine how thesystem should be used to cover the structures with the substrate and thecoating. The automated system can utilize a computational planner thatutilizes one or both of the models captured by the vision system and thebuilding plan to determine how the automated system will perform all orany of the steps in a sprayed-on walls process. The automated system canbe used to cut, trim, and/or finish the edges of the substrate material.The layout of the substrate can be optimized to minimize the number ofbreaks or seams in the substrate or to control the location of seams.The substrate material can be hung or attached to the structure manuallyor using the automated system. The substrate can be attached by nails,screws, staples, glue, anchors or any other suitable fixing component.The substrate material may be overlapped at breaks or can generateseams.

Turning to FIGS. 1 and 2, examples of an automated surface finishingsystem 100 are illustrated, which includes a base unit 120, a roboticarm 140 and an end effector 160. The base unit 120 comprises a platform122 and a cart 124 with a lift 126 disposed between the platform 122 andcart 124. The cart 124 can be configured to be disposed on the groundand move within an XY plane defined by axes X and Y, and the lift 126can be configured to raise the platform 122 up and down along axis Z,which is perpendicular to axes X and Y.

In the examples of FIGS. 1 and 2, the cart 124 can comprise a pluralityof wheels 128, which can be used to move the cart 124 and surfacefinishing system 100 on the ground in the XY plane. Such movement can bemotorized or can be non-motorized. For example, in some embodiments, thesurface finishing system 100 can be configured for automated movement ofthe cart 124, motorized movement based on input from a user and/ornon-motorized movement based on physical movement by a user.Additionally, while an example having wheels 128 is shown in someexamples herein, it should be clear that the cart 124 can be configuredfor motorized and/or non-motorized movement via any suitable structures,systems, or the like.

In the examples of FIGS. 1 and 2, the lift 126 is shown comprising ascissor lift that can raise and lower the platform 122 relative to thecart 124 along axis Z. Such movement can be motorized or can benon-motorized. For example, in some embodiments, the surface finishingsystem 100 can be configured for automated movement of the lift 126,motorized movement of the lift 126 based on input from a user and/ornon-motorized movement based on physical operation of the lift 126 by auser. Additionally, while an example of a scissor lift is shown herein,it should be clear that any suitable lift system can comprise the lift126 without limitation.

The platform 122 can comprise a hub 130, which can couple with therobotic arm 140 at a base end 142 of the robotic arm 140. The hub 130can comprise an input interface 132 that allows for various systems tocouple with the hub 130, which can allow for resources provided by suchsystems to be provided to the robotic arm 140 and/or the end effector160 coupled at a distal end 144 of the robotic arm 140 as discussed inmore detail herein. For example, a pneumatic source, a power source, avacuum source, a paint source, a coating or joint compound source, orthe like can be coupled to the hub 130. FIG. 1 illustrates an examplehaving an air compressor 134 and a vacuum source 136 coupled to the hub130. FIG. 2 illustrates an example having an air compressor 134 coupledto the hub 130, which can be used to power pneumatic actuators 146 ofthe robotic arm 140 and/or provide compressed air to the end effector160 at the distal end 144 of the robotic arm 140.

In various embodiments, the robotic arm 140 can comprise any suitablerobotic arm or positioning stage system, which can include pneumaticactuators, electric actuators, and the like. The robotic arm 140 canhave any suitable number of degrees of freedom. Although the examples ofFIGS. 1 and 2 illustrate an example having pneumatic actuator units 146separated by arm couplers 148, this example configuration should not beconstrued to be limiting on the wide variety of robotic arms 140 orpositioning stages that are within the scope and spirit of the presentdisclosure.

As discussed in more detail herein, an end effector 160 can be coupledat the distal end 144 of the robotic arm 140. In some examples, theautomated surface finishing system 100 can comprise modular and/ormulti-use end effectors 160, which can be configured for variousdrywalling, construction, or other tasks. For example, as discussedherein, end effectors 160 can be configured for substrate planning,substrate hanging, applying coating or joint compound to hung substrate,sanding the coating, painting, and the like. Although various examplesherein relate to drywalling and construction, further embodiments of thesurface finishing system 100 can be configured for any suitable tasks,including construction tasks, manufacturing tasks, gardening tasks,farming tasks, domestic tasks, and the like. Accordingly, thediscussions herein related to drywalling and construction should not beconstrued to be limiting on the wide variety of tasks that the system100 can be configured for.

Turning to FIG. 3, a block diagram of a surface finishing system 100 isillustrated, which includes a base unit 120 coupled to a robotic arm140, which is coupled to an end effector 160. The base unit 120 is showncomprising a control system 322, which is operably coupled to a visionsystem 324, sensors 326, and a movement system 328. The robotic arm 140is shown comprising sensors 346 and a movement system 348, which areoperably coupled to the control system 322. The example end effector 160is shown comprising a vision system 364, sensors 366, a movement system368, and one or more end effector devices 370, which are operablyconnected to the control system 322.

In various embodiments, the connections between the control system 322and respective vision systems 324, 364; respective sensors 326, 346,366; respective movement systems 328, 348, 368; and end effector devices370 can comprise any suitable type of connection including wired and/orwireless connections. For example, such connections can be configuredfor digital and/or analog communication of information betweenrespective elements.

The vision systems 324, 364 can comprise one or more suitable visionsystem including one or more visible spectrum camera, radar, lightdetection and ranging (LIDAR) system, sonar, infrared camera, thermalcamera, stereo cameras, structured light camera, laser scanners, and thelike. The vision systems 324, 364 can comprise the same or differentelements. Additionally, in some embodiments, one or both of the visionsystems 324, 364 can be absent. In some embodiments, the robotic arm 140can comprise a vision system.

The sensors 326, 346, 366 can comprise any suitable sensors in variousembodiments including one or more sensors of humidity, temperature, airflow, laser curtains, proximity sensors, force and torque sensors,pressure sensors, limit switches, rotameter, spring and piston flowmeter, ultrasonic flow meter, turbine meter, paddlewheel meter, variablearea meter, positive displacement, vortex meter, pitot tube ordifferential pressure meters, magnetic meters, humidity sensor,conductivity sensor and depth or thickness sensors. The sensors 326,346, 366 can comprise the same or different elements. Additionally, insome embodiments, one or more of the sensors 326, 346, 366 can beabsent.

The movement systems 328, 348, 368 can comprise any suitable movementsystems in various embodiments including one or more of an electricmotor, pneumatic actuators, piezo electric actuator, and the like. Forexample, in some embodiments the movement system 328 of the base unit120 can comprise the lift 126 and motors that drive wheels 128 of thecart 124 (see FIGS. 1 and 2). In another example, the movement system348 of the robotic arm 140 can comprise pneumatic actuators 146 asillustrated in the examples of FIGS. 1 and 2. In various embodiments,the movement system 368 of the end effector 160 can comprise motors orother systems that are configured to move, change the orientation of,rotate, or otherwise configure the end effector 160. In someembodiments, one or more of the movement systems 328, 348, 368 can beabsent.

As discussed herein, the one or more end effector devices 370 cancomprise various suitable devices, including a cutting device, hangingdevice, coating device, sanding device, painting device, vacuum device,and the like. Other suitable devices can be part of an end effector 160and can be selected based on any desired task that the end effector 160may be used for.

As discussed in more detail herein, the control system 322 can receivedata from the vision systems 324, 364 and sensors 326, 346, 366 and candrive the movement systems 328, 348, 368 and one or more end effectordevices 370 to perform various tasks including substrate planning,substrate hanging, applying coating or joint compound to hung substrate,sanding the coating, painting, and the like. Accordingly, the controlsystem 322 can drive the surface finishing system 100 to perform varioussuitable tasks, with some or all portions of such tasks being automatedand performed with or without user interaction. The control system cancomprise various suitable computing systems, including one or moreprocessor and one or more memory storing instructions that if executedby the one or more processor, provide for the execution of tasks by theautomated surface finishing system 100 as discussed in detail herein.Additionally, while a control system 322 is shown as being part of thebase unit 120, in further embodiments, the control system can be part ofthe robotic arm 140 or end effector 160. Also, further examples caninclude a plurality of control systems and/or control sub-systems, whichcan be suitably disposed in one or more of the base unit 120, roboticarm 140, and or end effector 160.

Turning to FIG. 4, an exemplary block diagram illustrating systems of anautomated surface finishing system 100 that includes a base unit 120coupled to a robotic arm 140 and including a plurality of end effectors160 configured to couple to the distal end 144 of the robotic arm 140.In this example, the end effectors 160 include a cutting end effector160C, a hanging end effector 160H, a coating end effector 160M, asanding end effector 160S and a painting end effector 160P.

As shown in FIG. 4, the base unit 120 can comprise a vacuum source 422,a paint source 426, a coating source 430, a power source 432, and one ormore base unit devices 438. In various embodiments, one or more of thevacuum source 422, paint source 426, coating source 430, and powersource 432 can couple with a hub 130 (FIGS. 1 and 2) and provideresources to an end effector 160 coupled at the distal end 144 of therobotic arm 140 and/or to the robotic arm 140. For example, the vacuumsource 422 can be coupled with a vacuum tube 424 that extends via therobotic arm 140 to an end 424E, which can couple with an end effector160 as discussed herein. The paint source 426 can be coupled with apaint tube 432 that extends via the robotic arm 140 to an end 432E,which can couple with an end effector 160 as discussed herein. Thecoating source 430 can be coupled with a coating tube 432 that extendsvia the robotic arm 140 to an end 432E, which can couple with an endeffector 160 as discussed herein.

The power source 434 can be coupled with a power line 436 that extendsvia the robotic arm 140 to an end 436E, which can couple with an endeffector 160 as discussed herein. Additionally, the power source 434 canprovide power to arm devices 442 of the robotic arm 140 (e.g., sensors346 and movement system 348) and to base unit devices 438 of the baseunit 120 (e.g., control system 322, vision system 324, sensors 326 andmovement system 328). In various embodiments, the power source cancomprise one or more batteries and/or can be configured to plug intowall receptacles at a work site. For example, a power cord can becoupled to the power source 438, which allow the surface finishingsystem 100 to be powered by local power at a worksite via a wallreceptacle, generator, external batteries, or the like. However, in someembodiments, the automated surface finishing system 100 can becompletely self-powered and can be configured to operate withoutexternal power sources at a worksite. In further embodiments, therobotic arm 140 and/or end effectors 160 can comprise a separate powersource that can be separate from the power source 438 of the base unit.

In various embodiments, the automated surface finishing system 100 canbe configured to perform a plurality of tasks related to installing andfinishing surfaces in construction. In such embodiments, it can bedesirable to have a base unit 120 and robotic arm 140 that can couplewith and operate a plurality of different end effectors 160 to performone or more tasks or portions of tasks related to drywalling. Forexample, the cutting end effector 160C, hanging end effector 160H,coating end effector 160M, sanding end effector 160S and painting endeffector 160P can be selectively coupled with the robotic arm 140 at thedistal end 144 to perform respective tasks or portions of tasks relatedto surface finishing.

For example, the cutting end effector 160C can be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower cutting devices 462 of the cutting end effector 160C. The cuttingend effector 160C can be controlled by the automated surface finishingsystem 100 to cut substrates or perform other cutting operations. Insome examples, the cutting end effector 160C can comprise a cuttingvacuum that is coupled to vacuum source 422 via the vacuum line 424 toingest debris generated by cutting done by the cutting end effector160C.

The hanging end effector 160H can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower hanging devices 464 of the hanging end effector 160H. The hangingend effector 160H can be controlled by the automated surface finishingsystem 100 to hang substrate, assist with substrate hanging, or thelike.

The coating end effector 160M can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower coating devices 466 and/or coating applicators 468 of the coatingend effector 160M. The coating end effector 160M can be controlled bythe automated surface finishing system 100 to perform “mudding” or“coating work” associated with surface finishing, including applicationof joint compound (also known as “mud”) to joints between pieces of hungsubstrate, and the like. Additionally, the coating end effector can alsobe configured to apply joint tape, or the like. Additionally, thecoating end effector 160M can comprise a coating vacuum 469 that iscoupled to vacuum source 422 via the vacuum line 424 to ingest excessjoint compound or coating generated by the coating end effector 160M.

The sanding end effector 160S can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower sanding devices 464 of the sanding end effector 160S. The sandingend effector 160S can be controlled by the automated surface finishingsystem 100 to sand coatings, and the like. Additionally, the sanding endeffector 160S can comprise a sanding vacuum 472 that is coupled tovacuum source 422 via the vacuum line 424 to ingest debris generated bysanding done by the sanding end effector 160S.

The painting end effector 160P can alternatively be coupled at thedistal end 144 of the robotic arm 140 and coupled with the power line436 to power a paint sprayer 474 and/or painting devices 476 of thepainting end effector 160P. The painting end effector 160P can becontrolled by the automated surface finishing system 100 to paintdrywall or other surfaces. Additionally, the painting end effector 160Pcan comprise a painting vacuum 472 that is coupled to vacuum source 422via the vacuum line 424 to ingest excess paint spray generated bypainting done by the painting end effector 160P.

Although the example automated surface finishing system 100 of FIG. 4 isillustrated having five modular end effectors 160, other embodiments caninclude any suitable plurality of modular end effectors 160, with suchend effectors 160 having any suitable configuration, and being for anysuitable task or purpose. In further examples, the automated surfacefinishing system 100 can comprise a single end effector 160, which canbe permanently or removably coupled to the robotic arm 140.Additionally, in some examples a given end effector 160 can beconfigured to perform a plurality of tasks. For example, in oneembodiment, an end effector 160 can be configured for coating work,sanding and painting. Accordingly, the example of FIG. 4 should not beconstrued to be limiting on the wide variety of other embodiments thatare within the scope and spirit of the present disclosure.

Turning to FIG. 5, a method 500 of drywalling is illustrated, which canbe performed in whole or in part by an automated surface finishingsystem 100 as discussed herein. The example method 500 or portionsthereof can be performed automatically by the automated surfacefinishing system 100 with or without user interaction.

The method 500 begins at 510, where a configuration and location ofsubstrate pieces is planned. As discussed herein, in various examples asubstrate can comprise one or more of mesh, paper, cloth surface, lath,buttonboard, rock lath, rainscreen, a porous surface, drywall board. Forexample, in some embodiments, the automated surface finishing system 100can be configured for automated scanning and mapping of a worksite(e.g., framing elements of a house or building) and automated planningof the shapes and sizes of substrate to be disposed at the worksite togenerate walls, ceilings, and the like. Such scanning and mapping caninclude use of vision systems 324, 364 (FIG. 3) and the like. Planningof shapes and sizes of substrate can be based at least in part on thescanning and mapping and can be performed by a computing device 100 ofthe automated surface finishing system 100 or other suitable devicewhich can be proximate or remote from the automated surface finishingsystem 100. In some embodiments, such planning can be based at least inpart on building plans or maps that were not generated by the automatedsurface finishing system 100.

The method 500 continues to 520, where substrate pieces are cut. Suchcutting can be based at least in part on the scanning, mapping andplanning discussed above. Additionally, such cutting can be performed bythe automated surface finishing system 100 at a worksite (e.g., via acutting end effector 160C) or can be performed by a system remote fromthe worksite and generated substrate pieces can be delivered to theworksite.

At 530, generated pieces of substrate can be hung at the worksite,including hanging on studs, beams, posts, wall plates, lintels, joists,and the like, to define walls, ceilings and the like. Screws, nails orother suitable fasteners can be used to hang the substrate. In someembodiments, the automated surface finishing system 100 can beconfigured to hang substrate including positioning the substrate andcoupling the substrate in a desired location. In some examples, theautomated surface finishing system 100 can be configured to assist auser in hanging substrate, including holding the substrate and/or toolsin place while the user fixes the substrate pieces in place. In variousexamples, a hanging end effector 160H can be used for such substratehanging.

At 540, coating work can be performed on the hung substrate. Forexample, a coating such as plaster, stucco, parex, gypsum, or the like(known also as “mud”) can be applied to seams or joints between adjacentpieces of substrate, over the substrate, and/or can be applied overfasteners such as screws or the like. In various examples, a coating endeffector 160M can be used to perform such coating work.

At 550, sanding can be performed on the coatings. For example, where wetjoint compound is applied to hung substrate, the joint compound can beallowed to dry and can then be sanded by a sanding end effector 160S ofan automated surface finishing system 100. In various examples, sandingcan be performed to smooth out joint compound to generate a planar orotherwise consistent profile on the pieces of substrate in preparationfor painting. At 560, the sanded substrate pieces can be painted. Forexample, in various examples, a painting end effector 160P of anautomated surface finishing system 100 can be used to paint the coating.

In some embodiments, after spraying the coating onto the substrate, thecoating can be worked into the substrate using trowels, edges, and othersuitable tools. This process can be done manually or using the automatedsystem 100. The tools may be powered using electricity, compressed air,hydraulics or a combination of these. The tools may be instrumented withsensors to measure humidity, pressure, viscosity, roughness, force, andlight reflectivity. After the coating has dried, it may be treated withmanual or powered tools to create the desired finish, texture, andmaterial properties. The tools may be used by workers or the automatedsystem 100 can use the tools to affect the surface. The system 100 mayuse tools such as sanders, polishers, powered trowels, or the like. Thetools or automated system(s) 100 may utilize vacuum systems to captureparticles or fumes. The sensors on the tools may be used to control theforce, pressure, speed with which the tools are used on the surface. Thesystem 100 may utilize sensors to capture the finish or texture of thecoating at different stages. Cameras, laser systems, texture analyzers,reflectivity sensor, conductivity measurements, and/or other contact ornon-contact systems may be used to determine the surface finish of thecoating and be used as feedback for the tools and process.

The coating can be combined with a paint, tint, pigment, or the likebefore and/or after application on a substrate or other surface. Thecoating can also be subsequently sprayed with a paint or sealant tocreate the finished surface after the coating is applied to a substrateor other surface. Tinted plaster, gypsum, or the like, can be sprayed tocreate a colored surface in a single coating. Other additives can alsobe mixed into the coating to control curing or drying time, surfacefinish, material properties, and the like. Material properties caninclude hardness, reflectivity, sound insulation, thermal insulation,fire rating, texture, finish, and the like. Accelerated curing or dryingof the coating can be achieved through light or temperature activationthat can be passive or active; via exposure to air as the coating issprayed; via addition of a chemical accelerant, curing agent, orcatalyst during mixing; during spraying or as an additional coating; orthe like.

Chopped fibers and other particles can be added to the coating before,during or after application to a substrate to create a composite. Thefibers can act to increase the strength of the coating and can createmechanical bonds to the substrate materials. The fibers can be addeddirectly into the mixture that can be pumped to a nozzle or such fiberscan be applied at a nozzle. The substrate can be covered in fibers orfeatures that the coating can attach to.

Tools such as a curing light, heater, or blower can be mounted on thesame tool as the sprayer to follow the delivery or can be mounted onanother suitable portion of the system 100 or separately therefrom.Additionally, the robotic system 100 can be used after spraying to movesuch a heater, blower, light, or other suitable tool or device over thesubstrate or surface. The velocity of the base unit 120 can becontrolled to set a given work time for each of the tools. The curing ordrying time can also be controlled by mixing powdered material with avolatile solvent instead of water.

Although the method 500 of FIG. 5 relates to hanging and finishingsurfaces, it should be clear that other hanging and finishing methodscan similarly be employed by the automated surface finishing system 100,including methods related to hanging particle board, plywood, sheetrock, laminate, tile, wall boards, metal sheeting, lath and the like.Similarly the methods can be used with different coatings includingplaster, polymer coatings, cement, stucco, organic coatings, and thelike. Accordingly, the method 500 of FIG. 5 should not be construed tobe limiting.

In one aspect, the present disclosure pertains to systems and methodsfor automated mixing, delivering, applying, curing, and/or dryingcoatings onto a substrate. In one embodiment, an automated surfacefinishing system 100 can be used to mix, deliver, apply, and drycoatings on substrates. The automated surface finishing system 100 canbe used to apply tape on seams between substrates, apply joint compoundor plaster onto the tape and substrate, expedite the drying process, orany combination of these processes. The automated surface finishingsystem 100 can also be used to apply the joint tape and compound andachieve any level of drywall finish including between level 0 and level5. The automated surface finishing system 100 can utilize joint compoundknown as mud or setting type compound also known as hot mud. Jointcompound as discussed herein can encompass pre-mixed, topping, taping,multi-use and all-purpose compounds. The automated surface finishingsystem 100 can also be used with other coatings including plaster,cement, stucco, and paint applied onto drywall, lath, mesh or anothersuitable substrate. The automated surface finishing system 100 can coverhow the coating is prepared, how it is delivered onto the substrate andhow it is set, cured or dried.

The automated surface finishing system 100 can include humidity,temperature, air flow sensors, or the like, to establish environmentalconditions for a task. Such sensors can comprise sensors 326, 346, 366of a base unit 120, robotic arm 140 and/or end effector 160 of theautomated surface finishing system 100 (see, e.g., FIG. 3). An automatedcoating system can utilize these environmental sensors to determineoptimal joint compound mixture ratios, set path parameters such as feedspeed, thickness of coating applied, blade profiles and pressures, andsprayer settings. The environmental information in conjunction with thecoating parameters can be used to determine or estimate drying andsetting times for the coating allowing the automated surface finishingsystem 100 to plan when a next step should begin.

The automated surface finishing system 100 can also determine when thecoating has set and dried by measuring the moisture content, thermalconductivity of the covered seam, using a thermal imaging camera orthermometer (contact or non-contact), detecting differences in colorsusing a camera, or the like. Thermal measurements can be used to inferthe moisture content by comparing the temperature of the coating to thesurrounding materials, and as the water evaporates from the mixture, thetemperature of the compound can be lower than that of the surroundingmaterials.

Models of the coating drying process can also be used to estimate thetime to dry or cure given a set of starting conditions and informationabout the environment. Similarly, the models of the coating incombination with environmental and substrate information can be used toestimate the drying shrinkage of the coating.

Environmental sensors can be used in conjunction with an HVAC system,heater, air conditioner, fans, or the like, to control the roomconditions. The sensor readings can trigger any of these systems or acombination to maintain the room at the desired conditions for quality,reduced drying or setting time, or comfort of the operator. In someembodiments, such environmental control systems can be a part of theautomated surface finishing system 100 or can be located external to theautomated surface finishing system 100 including environmental controlssystems of a worksite. Accordingly, in various embodiments, theautomated surface finishing system 100 can be configured to controlenvironmental control systems that are a part of or external to theautomated surface finishing system 100, including via wired and/orwireless communication.

A coating system can comprise of a variety of tools that enable thecoating system to mix, deliver, apply, smooth, dry, cure a coating, orany combination of these. Such tools can be positioned and controlledusing a robotic manipulator, robotic arm, positioning stage, gantry orany combination of these. A single end effector 160 or any multitude ofend effectors 160 can be used to complete the task through coordinatedor individual paths. The robotic arms 140 or tool stages can be movedaround the room using a mobile base unit 120 that can be powered ormoved manually by an operator. For example, in some embodiments acoating system of an automated surface finishing system 100 can includeone or more coating end effector 160M, and elements associate with thebase unit 120, including a coating source 430 (see FIG. 4).

The mobile base unit 120, one or more end effectors 160 and/or one ormore robotic arms 140 can include sensors (e.g., sensors 326, 346, 366as discussed in FIG. 3) to ensure safe operation next to the user.Safety sensors can include but are not limited to laser curtains,proximity sensors, force and torque sensors, pressure sensors, limitswitches, or the like. Additionally, the automated surface finishingsystem 100 can include systems to track location of one or more userrelative to end effector 160, robotic arm 140 and/or mobile base unit120, including speed limiters and/or vision systems, such as LIDAR,radar, sonar, or any combination of these (for example, vision systems324, 364 of FIG. 3).

As discussed herein, the mobile base 120 can include a vertical lift 126that can be powered or unpowered. The vertical lift 126 can be used tolift or lower the robotic arm 140, end effector 160 and portions of acoating system, which can be disposed on the end effector 160, platform122, a gantry or the like. The lift can be instrumented with a positionsensor that can be used to capture and control the height of the lift126. For example such a sensor can comprise the sensors 326 asillustrated in FIG. 3.

Elements of coating system of the automated surface finishing system 100can be controlled using the control system 322 that takes a variety ofinputs (e.g., from sensors 326, 346, 366 and/or vision systems 324, 364)to determine tool paths and/or tool parameters for the platform 122relative to the cart 124, robotic arm 140, and coating devices 468 andor coating applicator 466 of a coating end effector 160M, which arerequired to achieve desired coating characteristics.

In various embodiments, the automated surface finishing system 100 cancreate a map of the target surfaces such as pieces of substrate, jointsbetween pieces of substrate, and the like. This map or model can becreated by importing building information modeling (BIM) and/or 2D, 3Dplans into a planner system. The map can be created directly by thesystem by utilizing computer vision or mapping sensors to scan the room(e.g., the automated surface finishing system 100). The scanningtechnologies can include, and suitable devices including stereo cameras,structured light cameras, LIDAR, radar, sonar, laser scanners, thermalimaging or any combination of these components. For example, in someembodiments, such scanning or vision systems can comprise the visionsystems 324, 364

Uploaded 3D or 2D plans can be combined with field data to create a moreaccurate map of the environment in some examples. The data fromdifferent sources can be combined using key features and user input. Themap can include the location of framing studs, substrate joints,openings, protrusions, as well as pipes, electrical conduit, ventilationducts, and any other components installed on the walls or ceilings.These locations may have been derived from the uploaded plans, the roomscan, user inputs, and the like. To facilitate the creation of the map,a user can help identify features through analysis of images, tagging ofthe features physically or digitally. The user can physically tagcomponents using various suitable methods, including but not limited to,a laser, tags, markers or a combination of these. The scanning or visionsystem can pick up these tags or track them as the user moves around theroom and locates the features. The mapping system or planner can alsotake as an input a layout of how the substrate pieces were hung in theroom to locate seams. This layout can be an input from the automatedsurface finishing system 100 or a system that is separate from theautomated surface finishing system. The location of framing, type ofanchors used and layout of the substrate can provide information on theplanarity, flatness of the wall, and location of high or low points,which can be used determine tool paths and tool parameters.

The automated surface finishing system 100 can include a computationalplanner (e.g., implemented by the control system 322 of the base unit100) which can utilize a map uploaded to the system 100 or created bythe system 100 to determine tool paths and/or tool parameters to achievea desired coating application. The planner can create toolpaths off aglobal map of a room and then update these paths given updated localmeasurements once the end effector 160, robotic arm 140, and/or mobilebase 120 are in place. The planner can be informed by vision system data(e.g. obtained by one or both of vision systems 324, 364) on theflatness of the wall, user inputs, location of seams as specified by alayout planner or a scan of the room after the substrate was applied.The planner can determine toolpaths and/or tool parameters to enable theautomated surface finishing system 100 to apply coating to smooth outjoints, seams, low points, high points, and other features to create avisually flat wall.

For example, tool paths can include information corresponding to, orused to determine, instructions for one or more of movement systems 328,348, 368 to drive the base unit 120, robotic arm 140 and/or end effector160 to move to perform desired tasks, including applying coating,applying joint tape, and the like. Tool parameters can include varioussetting for components of the end effector 160 (e.g., setting for thecoating applicator 466 and/or coating devices 468 of a coating endeffector 160M), including a nozzle selection, a nozzle size setting,coating flow rate, and the like as discussed in more detail herein.

The toolpaths and/or tool parameters can also be determined based on adesired or required finish for completed coating work or for a completedwall assembly. For example, areas of a wall or ceiling that are exposedto changing, harsh, or bright lights can receive a higher quality finishwith tighter controls on tool planarity, tool overlaps, thickness andcharacteristics of compound applied, texture.

The application of coating to a surface can inform how the surface is tobe sanded, smoothed or polished to achieve a desired finish. Forexample, toolpaths and/or tool parameters generated during coating workcan serve as inputs for generating toolpaths and/or tool parameters forsanding, which in some examples can enable sanding to be tuned accordingto the application of the compound, features, and compoundcharacteristics such as how the compound was dried, compound type,compound hardness, and layers of compound applied.

For example, the automated surface finishing system 100 can determinetoolpaths and/or tool parameters for performing mud work with a coatingend effector 160M, and these determined toolpaths, tool parameters,and/or data associated thereto can be used to determine toolpaths and/ortool parameters for one or more sanding tasks to be performed by theautomated surface finishing system 100 using a sanding end effector160S.

Similarly, determining toolpaths and/or tool parameters for performingcoating work with a coating end effector 160M can be based on varioussuitable inputs, including toolpaths, tool parameters, and/or the likeassociated with hanging substrate or applying insulation to a wallassembly on which the substrate is hung. For example, the automatedsurface finishing system 100 can determine toolpaths and/or toolparameters for performing substrate hanging with a hanging end effector160H, and these determined toolpaths, tool parameters, and/or dataassociated thereto can be used to determine toolpaths and/or toolparameters for one or more coating tasks to be performed by theautomated surface finishing system 100 using a coating end effector160M.

During coating work, automated surface finishing system 100 can apply alayer or profile of compound that is greater than a thickness that canbe conventionally manually applied by human workers to allow for asanding system (e.g., a sanding end effector 160S) to sand down thecompound to a desired plane. For example, in some examples, manual jointcompound application mud can be profiled to taper from high points. Theautomated surface finishing system 100 can apply a thicker layer thannormal enabling a sanding system to sand down high points to be level tothe adjacent surfaces.

For example, related applications that are incorporated hereinillustrate one example of a mud application profile for a pair ofdrywall pieces that form a seam, where joint compound is applied overconsecutive layers, which can include joint tape, to taper out the highpoints of joint compound over a wider area. Sanding can then be used tosmooth out the final profile. The high points of joint compound can becaused by various features, including the seam, feature, raised stud,defect, or any combination of these. In some embodiments, such a mudapplication can be undesirable for automated application; however, infurther embodiments, such a mud application profile can be employed byan automated system such as the automated surface finishing system 100.

As discussed herein, various types of substrates can be used to generatea wall assembly including a substrate that comprises mesh, paper,plastic, cloth surface, lath, buttonboard, rock lath, rainscreen,drywall board, a porous surface, or the like. For example, FIG. 6aillustrates an example of a two-layer substrate 610 that comprises aporous layer 611 and a less-porous layer 612. The porous layer 611 canhave pores where the coating material can enter and adhere, while theless-porous layer 612, which can be attached to a wall or studs, can benon-porous and impermeable to the coating material such that the coatingmaterial does not impregnate or permeate through the less-porous layer612. For example, the less-porous layer 612 can stop the coatingmaterial from reaching the opposing side of the substrate. In furtherembodiments, the less-porous layer 612 can be porous such the coatingmaterial is able to soak through, impregnate, or permeate at least aportion of the less-porous layer 612.

Such a configuration of a multi-layer substrate 610 comprising a porouslayer 611 and a less-porous layer 612 can be desirable for allowing afluid coating material to be applied to the substrate 610 as describedherein, and when the fluid coating material dries to become rigid ornon-fluidic, the porous layer 611 can provide a support matrix for driedcoating material to improve the strength of the dried coating materialand/or to assist with coupling the dried coating material to theless-porous layer 612 and thereby to the wall or studs that theless-porous layer 612 is coupled to.

Such a multi-layer substrate 610 comprising a porous layer 611 and aless-porous layer 612 can have various suitable configurations. Forexample, the porous layer 611 and a less-porous layer 612 can bephysically separate layers that are coupled via an adhesive, weld, orthe like. In other examples, a portion of the porous layer 611 can beembedded in a portion of the porous layer 611 or the porous layer 611can be an integral part of and can extend from the less-porous layer612.

Also, one or both of the porous layer 611 and less-porous layer 612 canbe rigid or flexible. For example, the less-porous layer 612 cancomprise a rigid drywall board or piece of wood and the porous layer 611can comprise a flexible cloth or batting. In further examples, both theporous layer 611 and less-porous layer 612 can be flexible (e.g., theless-porous layer 612 can comprise an impermeable or semi-permeablepaper or plastic and the porous layer 611 can comprise a flexiblepermeable matrix or mesh of a suitable material. Having both the porouslayer 611 and less-porous layer 612 being flexible can be desirablebecause such a configuration can allow the substrate 610 to be stored inrolls and applied to studs or a wall via the roll, which may or may notinclude cutting of the substrate 610.

Although various examples include application of the substrate 610 to awall or studs with the porous layer 611 and less-porous layer 612 beingcoupled together, in further embodiments, the porous layer 611 andless-porous layer 612 can be applied separately. For example, theless-porous layer 612 can be first applied, and then the porous layer611 can be applied to the less-porous layer 612.

Various embodiments can include selecting, configuration or changingproperties of the substrate 610 to address different surfaces such aswalls or ceilings or to control the target finish. The porosity,absorption properties, mesh size, wettability, adhesion properties,anchor spacing, substrate thickness and material composition may becontrolled in the substrate to achieve the desired finish or addressvertical vs horizontal surfaces. A backing material (e.g., theless-porous layer 612) may be used behind a mesh or porous surface(e.g., the porous layer 611) to set the thickness of the coating. Thematerial thickness of the substrate 610 and/or spacing between substrate610 and structural surfaces such as studs may also be used to controlthe thickness of the coating. The substrate 610 can comprise two or moredifferent materials or mesh sizes as a way to control the thickness ofthe surface. For example, the substrate 610 can comprise any suitableplurality of different layers including two, three, four, five, six, orthe like.

In some embodiments, the substrate 610 can be instrumented with one ormore sensors that can measure humidity, temperature, conductivity,sound, or the like, which can be used to provide feedback during thespraying process; to serve as in wall-sensors for detection of leaks inthe walls, temperature and humidity of the room, or environmentalproblems; or for other suitable purposes. For example one or both theporous layer 611 and less-porous layer 612 can comprise any suitabletype of sensor. In some examples, such sensors can each wirelesslycommunicate with the system 100. In other examples, such sensors can beoperably coupled (e.g., wirelessly or via a wire) to a wall assemblydevice, home automation system, or other suitable system and the surfacefinishing system 100 can communicate wirelessly with such a system ordevice.

Also, while the example of FIG. 6a illustrates a substrate 610 having aplurality of layers, further examples can include a substrate having asingle layer as shown in FIG. 6b , which illustrates a substrate 610consisting essentially of a less-permeable layer 612. However, infurther embodiments, a substrate can consist essentially of the porouslayer 611 or less-porous layer 612.

FIGS. 7a and 7b illustrate an example joint compound application processwhere the coating 630 is applied in a thick layer using a sprayer thatgenerates a mud spray 700. Such an application process can be performedby the automated drywalling system 100 in various embodiments. Thethickness of the coating 630 being applied to the pieces of substrate610A, 610B defining a seam 620 can allow for a sanding system to be usedto sand back high points of coating 630 to a level surface. The highpoints of coating 630 can be caused by the seam 620, feature, raisedstud, defect, or any combination of these.

The substrate 610 and sprayed coating 630 can be used as a stand-alonewall coating system for single-coat applications or as part of amulti-coat wall coating system. A multi-coat wall coating system cancomprise two or more layers of the same or different materials appliedmanually and/or with automation. This can allow for an automatedapplication of a coating 630 to the substrate 610 with desirablestructural properties to be followed by an application of a coating 630with desirable aesthetic finishing properties.

In some embodiments, a substrate 610 can have coating 630 applied asshown in FIGS. 7a, 7b or via other suitable methods as discussed hereinand/or the substrate 630 can be pre-impregnated with a coating material630 prior to hanging or it may be impregnated by one coating followed bya second material. The substrate 630 can be impregnated with a materialsimilar to pre-preg composites. The coating material 630 in thesubstrate 610 can be activated or wetted by spraying a liquid materialover it the coating material 630 to convert the impregnated materialinto a rigid coating. The coating 630 may be electrostatically chargedand the substrate 610 grounded to accelerate coating particles towardsthe substrate 630 and improve adhesion and/or reduce overspray of thecoating 630. The coating 630 can contain additives to facilitateelectrostatic charging.

The 2D or 3D maps created by the automated surface finishing system 100can be registered to the physical environment utilizing recognizablefeatures such as doors, windows, outlets, corners, or the like. Suchregistration can also be done using markers, tags, laser outlines thatare placed in the room, or the like. A projection and/or visualizationsystem of the automated surface finishing system 100 can find thefeatures or markers and can locate the maps created using these foundfeatures or markers. The automated surface finishing system 100 canutilize a user interface to enable the user to help locate the map orprojection relative to the environment and resolve any issues ordiscrepancies. A user can utilize a physical marker to signify keyfeatures for the automated surface finishing system 100 allowing theautomated surface finishing system 100 to locate the plan relative tothe environment. The automated surface finishing system 100 can also usea robotic manipulator or end effector 160 to find target features,markers or surfaces and locate them relative to its own base unit 120which can be located using a localization system including, but notlimited to laser range finders, computer vision, LIDAR, radar, sonar,stereo vision, odometry, IMUs, or any combination of these.

The robotic arm 140 can utilize a compliant or force limiting endeffector 160 to enable safe contact with the environment allowing theautomated surface finishing system 100 to accurately locate targetsurfaces, features or components, accommodate errors in positioningwithout damaging the substrate or the end effector 160. By utilizing therobotic arm 140 and compliant end effector 160 to locate a physicalcomponent, the system 100 can establish a point, line, or plane andtherefore locate the virtual plan on the environment. Toolpaths can beupdated from the virtual plane to the physical plane. Refitting of thetoolpaths onto the contacted surfaces can enable the system 100 to dealwith errors and discrepancies between the modeled and physicalenvironment. Such tools, features or elements of the system 100 canenable quick on-site calibration using global room wide maps and localmeasurements. Refitting the toolpaths can allow for errors inpositioning of end effector 160, mobile base 120 or robotic arm 140. Thesystem 100, including an end effector 160 can utilize radar, sonar,thermal imaging to establish what is behind the substrate (e.g.,drywall), this information can be used to update a virtual map andensure that no damage is done to any electrical, plumbing or ventilationwhile working on or about the substrate.

The planner can output tool poses or tool paths for the automatedsurface finishing system 100 (e.g., for an end effector 160, robotic arm140, base unit 120) including, but not limited to joint commands, targetposes and end effector positions, or any combination of these. Thesystem 100 can also output paths for a gantry system or positioningstage which can be used in conjunction with the robotic arm 140 and/orend effector 160 or without a robot to move and position coating tools(e.g., coating devices 466 and/or coating applicators 468 of a coatingend effector 160M). The planner can also output paths for the mobilebase 120 to position a gantry, positioning stage, robotic arm 140, endeffector 160, or to move a tool to assist a user in the finishingprocess, or to position visualization and lighting equipment, which mayor may not be a part of the automated surface finishing system 100. Themobile base 120 and vertical lift 126 may work in coordination with auser, robotic arm 140, end effector 160 or a combination of these toexecute the task. The planner system can control different components ofthe automated surface finishing system 100 (e.g., the base unit 120,robotic arm 140 and/or end effector 160) allowing for coordinatedmovements and forces with the target goal of moving the end effector 160or portions thereof to a desired position under the prescribed forcesand moments. The mobile base unit 120 can be used as a rough positioningstage, with the vertical lift 126 setting the height of the robotic arm140 and end effector 160 which may act as a fine positioning stage.

Turning to FIGS. 8a, 8b, 9a and 9b , examples of a wall assembly 800including a plurality of substrate pieces 610A, 610B, 610C, 610D isillustrated. The wall assembly 800 can comprise a header 810 and footer820, with a plurality of studs 830 extending therebetween as shown inFIG. 8a . As shown in FIG. 8b , the substrate 610 can be coupled to thestuds 830 via a plurality of fasteners (e.g., drywall screws) thatextend though the substrate 610 and into the studs 830. The substrate610 can define one or more seams 620, including in the example of FIG. 8b a vertical seam 620V and a horizontal seam 620H. In some embodiments,coating work can be performed on the seams 620 as shown in FIG. 9a andleaving portions of the substrate 610 without coating 630. Additionallyor alternatively, coating can be applied to portions of the substrate610 in addition to about the seams 620 as shown in FIG. 9 b.

FIG. 10 illustrates one example embodiment of the automated surfacefinishing system 100, having a coating end effector 160M that isconfigured to generate a coating spray or line. In this exampleembodiment, the system 100 is shown comprising a robotic arm 140 with acompound spraying or extruding end effector 160. The robotic arm 140 andend effector 160 are shown mounted on a mobile base 120 with a verticallift 126. The base unit 120 can carry supporting systems for theautomated surface finishing system 100 as discussed herein.

An end effector 160, such as the embodiment 160M1 of a coating endeffector 160M, shown in FIG. 11 can utilize a tool to automaticallydispense and apply joint tape 640 at the seams 620 between substratepieces 610. In this example embodiment 160M1, coating 630 can bedispensed from a flat box 1110 and joint tape 640 can be dispensed froma roller 1120. The joint tape 640 can come into contact with thecompound before a blade 1130, which can be used to apply the joint tape640 and joint compound 640 onto the seam 620. The blade 1130 can smooththe tape 640 down and can apply the joint compound 640 on the seam 620.

In one embodiment, joint tape 640 can be fed off a roll 1120 onto ajoint 620 defined by a first and second substrate piece 610A, 610B afterbeing covered with coating 630. In some embodiments, coating 630 can bedelivered ahead of the tape 640 and the 640 tape can be flattened ontothe surface of the substrate pieces 610 and seam 620 using a blade ortrowel 1130. The end effector 160 or other portion of the system 100 canalso be used to automatically apply the tape 640 using tools such asbanjo and bazooka systems. Tracking the position of the end effector 160and portions thereof with devices, sensors, vision systems or otherelements of the end effector 160, robotic arm 140 and/or base unit 120can enable the planner to create an updated map of the room with thelocation of the tape 640 and/or coating 630 and the conditions underwhich one or both were applied.

One or more vision system 324, 364 can also use tags or markers to trackas an end effector 160 or as a user applies tape 640 on the surfacesand/or seam 620 of one or more substrate pieces 610 and that informationcan be communicated to and stored by the planner. The end effector 160and/or robotic arm 140 can be used to control the orientation of toolsor devices of the end effector 160 and the force applied on a surface astape 640 is applied, which can be desirable in some examples to ensurethat the tape 640 is embedded within coating 630 as desired. The surfacefinishing system 100 can apply, solid, porous and/or mesh joint tape 640with or without adhesive that can be covered with coating 630 using aseparate tool or a tool associated with an end effector 160.

Joint tape 640 can be applied by the automated surface finishing system100 and/or by an operator. Additionally, in some embodiments, joint tape640 can be colored, dyed or marked so that it is easier for a visionsystem 324, 364 to identify the joint tape 640. Different color tapes640, or tapes 640 having different identifying features (e.g., textures,images, barcodes, or the like) can be used in some embodiments toprovide information to the automated surface finishing system 100 aboutthe identity or characteristics of a specific joint 620 or other featureof one or more piece of substrate 610. For example, butt joints can becovered with a first color tape 640, tapered joints can be covered witha second color tape 640, and factory joints can be covered with a thirdcolor tape 640. An end effector 160 can also use a coating 630 thatcomprises fibers in addition to, or as an alternative to, tape 640. Oneor more vision system 324, 364 can be used to identify seams 620 betweensubstrate pieces 610 and data from such vision systems 324, 364 can beused to guide an end effector 160 during taping. The end effector 160can also be guided using the planner's map of the surface which islocated on the environment using relevant features such as markers,corners, openings, or the like.

The coating 630 can be delivered or applied onto joint tape 640, seams620 and/or surfaces of substrate pieces 610 using a variety endeffectors 160 having a variety of elements, devices, or tools. Forexample, FIG. 12 illustrates one embodiment 160M2 of a coating endeffector 160M that includes a spray gun 1210 that is coupled onto therobotic arm 140. A trigger 1220 can be actuated with an actuator 1230(e.g., a servo, solenoid, pneumatic cylinder, or the like) which canpull on the trigger 1220 to open the nozzle 1240 to generate a coatingspray 700.

In another example, FIG. 13 illustrates another embodiment 160M3 of acoating end effector 160M that includes a spray gun 1210 that is coupledonto the robotic arm 140. An internal trigger (not shown) can beactuated with an actuator (e.g., a servo, solenoid, pneumatic cylinder,or the like) which can open the nozzle 1240 to generate a coating spray700. In the examples of FIGS. 12 and 13, coating can be fed to the spraygun 1240 and nozzle 1240 via a coating tube 432, which can feed coating(e.g., joint compound, or the like) from a coating source 430 disposedat the base unit 120 (See FIG. 4).

In various embodiments a spray gun 1210 can comprise an airless spraysystem or air assisted spray system. A pump can be used to move thecoating 630 from the coating source 430 to the spray gun 1210. Thecoating 630 can be pumped at high pressures, in some examples, to enablethe coating 630 to be sprayed or aerosolized. In some examples, highjoint compound particle speeds can produce a smoother finish, which canbe desirable in some examples.

The pressure, flow rate, piping system resistance and the like, can betuned or controlled by the automated surface finishing system 100 tochange the speed and amount of coating 630 being delivered to the spraygun 1210 and ejected from the nozzle 1240 as a spray 700. The automatedsurface finishing system 100 can use any suitable actuator (e.g., aservo, solenoid, air cylinder, linear actuator, or any combination ofthese) to open and close the nozzle 1240 of the spray gun 1210. As shownin the example of FIG. 12, a manual spray gun 1210 can be instrumentedto use an electro-mechanical system 1230 to pull the trigger 1220allowing the system 100 to control the timing of the coating delivery aswell as the opening and closing of the nozzle 1240.

As shown in the example of FIG. 13, an automatic spray gun 1210 can alsobe used and controlled by the system 100 directly. The robotic arm 140and end effector 160 and/or base unit 120 can thereby be used to spraythe coating 630 as a spray 700 onto substrate pieces 610 and/or seams620 defined by one or more substrate pieces 610. The coating 630 can besprayed before and/or after applying joint tape 640. The automatedsurface finishing system 100 can use a mesh or porous tape 640 in someexamples to allow the coating 630 to be sprayed through the joint tape640 to fill a gap under the joint tape 640 (e.g., a seam 620 or thelike).

The spray gun 1210 can use a variety of suitable nozzles 1240 includingfan shape, bell shape, or the like. The system 100 can also use atunable spray gun 1210 that can control the shape of the nozzle 1210.The shape of the coating spray 700 may be controlled in some examples byphysically changing the shape of the nozzle 1210. The shape of thecoating spray 700 can also be controlled using air streams, or the likewhich can act on the coating spray 700.

In some embodiments, a cassette with different nozzles 1240 can beinstalled on the spray gun 1210 allowing the automated surface finishingsystem 100 to select a desired nozzle 1240 to control the shape of thespray 700. A fan shape can also be tuned by using a set of slidingmechanisms to set the fan width and opening of the nozzle 1240. Thediameter of a bell may also be tuned by a sliding cone with expandingorifice size. The robotic arm 140 and/or base unit 120 can also be usedto move the nozzle 1240 closer or farther away from a target surfaceresulting in a narrower or wider fan or bell spray pattern respectively.The system 100 can utilize an array or series of nozzles 1240 to spraythe coating over a larger surface. The nozzles 1240 can be individuallycontrolled and tuned or such nozzles 1240 can be controlled as a unit.

A series of tests can be performed to establish the characteristics of apattern of coating spray 700 delivered by a nozzle 1240. In oneembodiment, one or more vision system 324, 364 can be used tocharacterize a pattern of coating spray 700 and provide feedback fortuning parameters including tool parameters related to a nozzle 1240,spray gun 1210, coating source 430, or the like, as discussed herein.Another embodiment can utilize an array of sensors (e.g., piezo sensorsor other force sensors) on a test board which can be used to measure theforce applied by the pattern of coating spray 700 as it hits thesensors. The force pattern can be used to estimate a profile of thepattern of coating spray 700 as it is hitting the surface. The feedbackfrom these sensors may be used to tune the profile of one or more spraynozzles 1240, spray gun 1210, coating source 430, or the like.

The automated surface finishing system 100 can include a mixer, pump andthe like that can deliver mixed coatings 630 to the various toolsincluding a spray gun 1210. Such a mixer, pump and the like can be partof a coating source 430 disposed at the base unit 120 or disposedexternal to the system 100. A mixer may utilize sensors to control amixing ratio of water, slurry or dry compound, and any additives thatenhance structure of the compound, color the compound, decrease settingor drying time, or the like. The mixer can control the mix ratio bymeasuring the mass, volume, density, or viscosity of the components orthe mixture that defines coating 630 or portions thereof. The mixingsystem can utilize pre-mixed coating 630 and can add water and/oradditives as desired.

The automated surface finishing system 100 can also use a spray gun 1210that has been designed to mix the components of the compound at thenozzle 1240. For example FIG. 14 illustrates an example of an in-linenozzle 1240 for mixing the coating compound 630, water, and anyadditives at the application site. The nozzle 1240 can be detachable insome examples to be cleaned or to be disposable.

In various embodiments, a nozzle 1240 can deliver a controllable ratioof water, air, slurry or dry coating compound, as well as additives thatmodify the coating, including enhancing the structure of the coating,color the coating, or decrease or increase setting or drying time.Nozzles 1240 as discussed herein can be used with any suitable type ofcoating, compound 430, or other material that can be sprayed, includingbut not limited to hot mud, plaster, or other curing compounds that setand cannot be washed off with water.

Compound lines 432, nozzle 1240, a pump, or the like, can beinstrumented with sensors to measure flow rate, pressure and otherdesirable parameters. Pressure sensors can be used to monitor thepressure along a compound line 432 enabling the detection of changes inthe pressure, flow rate, as well as the detection of clogs. In someexamples, an orifice plate may be used to measure the flow rate throughthe coating system in combination with a set of pressure sensors. Otherflow rate sensors can include, but are not limited to a rotameter,spring and piston flow meter, ultrasonic flow meter, turbine meter,paddlewheel meter, variable area meter, positive displacement, vortexmeter, pitot tube or differential pressure meters, or magnetic metersfor conductive coatings. Detecting a change in flow, pressure in thecoating line 432, or reaction force at the end effector 160 (e.g. at aspray gun 1210) can be used to determine that a clog has occurred. Thespray gun 1210 can produce a reaction force when spraying so if thatreaction force changes the system 100 can identify that the spray 700has changed, which can be indicative of a clog or other issue.

A pattern of the coating spray 700 can also be monitored to detect clogsor wear of the nozzle 1240. For example, FIG. 15 illustrates an exampleembodiment 160M4 of a coating end effector 160M that includes a spraypattern detection mechanism 1505, in which a vision system 364 can beused to monitor the pattern of coating spray 700 coming out of thenozzle 1240 to detect clogs, nozzle wear, low pressure, or otherproblems with the spray gun 1210 or related system such as coating lines432, coating source 430 or the like.

In some examples, the stream of coating spray 700 can be monitored orthe pattern of coating spray on a target wall can be monitored. Thestream of coating spray 700 and/or pattern of coating spray 700 can bemonitored using vision sensors 364, which can include any suitablevision system, including but not limited to thermal sensors, moisturesensors, capacitance sensors, or the like.

In one embodiment, a camera can be placed next to the stream of coatingspray 700 so that the profile of the coating spray 700 is captured.Image processing can be used to identify when the shape of the stream ofcoating spray 700 has changed. In another embodiment a laser curtain maybe placed across the stream of coating spray 700, if the flow isinterrupted along any part of the fan or bell the laser would completeits path and be detected by a sensor on the other side of the stream ofcoating spray 700.

A mixer, pump, coating lines 432, and nozzle 1240, and other suitableelements can be fitted with filters which can be used to catch debris orparticles that may clog the nozzle 1240 or coating lines 432. Thefilters can be placed an inlet of the pump, outlet and inlet of themixer, directly before the coating line 432, directly before the nozzle1240, or any point along or within the coating system. The automatedsurface finishing system 100 can monitor the pressure before and afterthe filters to detect when the filters need to be changed. Flow ratesensors can also be used to detect a clogged filter. The automatedsurface finishing system 100 can reverse its flow to clear clogs fromthe coating line 432, nozzle 1240, filters, or other components.

The spray gun 1210 or other coating end effector 160M may also include avacuum system 469, spray guards, or the like, that can be used tominimize overspray and reduce the amount of excess coating 430 in theair. For example, FIG. 16 illustrates an example embodiment 160M5 of acoating end effector 160M that comprises a vacuum system 469 thatincludes a vacuum hood 1605 disposed around an end and nozzle 1640 of aspray gun 1610 to capture overspray. The vacuum hood 1605 can surroundthe spray gun 1210 and can include an adjustable vacuum setting. Thevacuum hood 1605 can be coupled to the vacuum line 424, which isconnected to the vacuum source 422 to provide a vacuum to the vacuumhood 1605.

FIG. 17 illustrates an example embodiment 160M6 of a coating endeffector 160M that comprises a spray guard 1705 that partially extendsabout and past the face of the nozzle 1260 of the spray gun 1210. Inthis example, the spray guard 1705 is shown being generally triangularand fanning out from where the spray guard is coupled to the endeffector 160M. In some examples, the spray guard 1750 can be selectivelydeployed by the system 100 or a user to prevent overspray onto anundesired surface. The spray guard 1705 can be deployed in varioussuitable ways, including but not limited to, via a servo, pneumaticcylinder, solenoid or other electromechanical actuator, which can rotateor otherwise deploy the spray guard 1705 into place.

In various embodiments, a coating end effector 160M can comprise one orboth of a vacuum system 469 and spray guard 1705 of various suitableconfigurations. The guard 1705 and/or vacuum system 469 can be deployedwhen the automated surface finishing system 100 is spraying near anothersurface or a feature. The spray guards 1705 and/or vacuum systems suchas a vacuum hood 1605 can be retracted using a linear actuator,solenoid, air cylinder, or other suitable electro-mechanical actuator.In some embodiments, a spray guard 1705 can also be mounted on a rotarystage such that the spray guard 1705 can be rotated into place next tothe sprayer 1210 by actuating the motor or servo. Accordingly, in someexamples, the position of the spray guard about a circumference of thespray gun 1210 can be selected by the system 100 and/or a user.

In some embodiments, coating 630 can be applied and/or smoothed by usinga blade that is dragged over applied coating 630. Such a blade can bepart of an end effector 160 having a spray gun 1210 or can be a separateend effector 160. In some embodiments, a coating end effector 160M canapply coating 630 and tape 640 at the same time for a layer, or canapply coating 630 over the tape 640 that has been previously applied.The shape, profile, and size of a coating blade can be controlled todeliver a desired profile of coating 630. Similarly, the pressure orforce on the coating blade can also be controlled to change thethickness and profile of the applied coating 630, which can be based ondata from the system 100 obtained from one or more vision system 324,364, sensors 326, 346, 366, or the like.

The automated surface finishing system 100 can also include a coatingend effector 160M that comprises a coating flat box 1805 to apply thecoating 630 as illustrated in the example embodiment 160M7 of FIG. 18.In various embodiments, the automated surface finishing system 100 canmove the box 1805 along the seam 620. An actuator 1810 can control theshape and/or position of a blade 1815 to tune the profile of coating 630applied on the seam 620. Various tool parameters, including box openingsize, blade size, blade shape, and the like, can be controlled tosimulate different sized boxes that are used to create a profile thatfeathers or blends a defect created by the seam 620 over a large portionof the substrate 610 to simulate flatness.

The end effector box 1805 can be automatically fed using a coating pumpand coating line 432. The coating end effector 160M may also includesensors 366 (e.g., proximity, force, contact sensors) to ensure that thebox 1805 is in contact with the substrate 610 during the application ofcoating 630. Additionally, a vision system 364, 324 of the end effector160 or base unit 120 can also be used to ensure that the flat box 1805is in contact with the surface of the substrate 610 during applicationof coating 630.

In some embodiments, a coating end effector 160 can deliver coating 630through a sprayer 1210 and/or nozzle 1240 and then utilize a physicalblade, trowel, air blade, roller or any other type of forming mechanismto smooth and profile the coating 630. The coating end effector 160M canutilize surrounding surfaces as datums. For example, a roller, wheel,blade, or the like, can be pushed in contact with the datum surface forreference. These contact points can extend away from a coatingapplication zone to enable the use of datums away from the defect orjoint 620. The coating end effector 160M can control the position of thecontact points such that the correct or optimal datum surface is used.The force and pressure on the contact points may also be controlled.Force may be directly measured or estimated by monitoring the deflectionof the mounting structure.

The coating tools can be mounted in series with a structure that limits,sets, or controls the amount of force applied on a target surface. Thestructure can limit, set or control the normal force applied on thesurface by the blades, rollers, trowels, and the like, and/or it canlimit, set or control forces applied by the tools along the targetsurface as well as torques applied. Such blades or rollers can bemounted on an air bag, air shock, air cylinder, air bellows, with afixed or variable pressure setting. The pressure and the normal area ofthe pressure vessel can set the amount of forces applied by the tool onthe target surface. The blade or roller can also be mounted on a spring,tunable spring, shock, or the like, in order to set, limit or controlthe forces applied on the target surface. The forces may also be set,limited, or controlled using a pressure controlled hydraulic systemincluding, but not limited to a cylinder, bellows, or reservoir. In oneembodiment, a short-stroke low-mass end effector linear actuatormechanism can be used for fast tracking of surface contours and constantnormal force. In embodiments with more than one blade or roller, thetools can be mounted on a single force limiting structure, or each heador multiple tools can be mounted on separate structures. Mounting thetools or group of tools on separate structures can allows for theapplied forces and moments to be set, limited, or controlled separately.

Coating tools can include sensors 366 and/or a vision system 364 toensure the desired orientation of the blades or rollers relative to thewall. For example, one application includes ensuring planarity of thetool to the wall; however, the mechanism may also set the blade orroller to a specific target angle relative to the surface. The planaritymay be established by utilizing the vision system 364 to detect theplane of the surface and then match the tool position using the degreesof freedom of the system 100. The planarity may also be established byutilizing one or more sensor 366 at the end effector 160 (e.g., a set ofproximity, range, or contact sensors to establish the position of a toolhead relative to a wall). Blade or roller orientation can be controlleddirectly by setting the joint angles of the robotic arm 140, by apowered gimbal or joint at the end effector 160, and/or by a passivegimbal that allows the tool to tip and tilt relative to the end of therobotic arm 140. A passive gimbal can enable the contact tool to followthe plane of a target surface despite errors in the position of thesystem 100.

In another embodiment, the position of the contact may be controlledthrough the active gimbal using feedback from one or more of sensors366, 346, 326 and/or vision systems 364, 324 that can establish therelative orientation between blades or rollers and surface. Powered orpassive gimbals or end effector degrees of freedom can be encoded (e.g.,via sensors 366) such that the orientation of the tool and/or endeffector 160 is known to the system 100.

A coating end effector 160M can also utilize outriggers such as rollersto use adjacent surfaces or raised edges as datums to guide theapplication of coating 630 and achieve accurate corners. These rollersmay be instrumented with sensors 366 and/or a vision system 364 tomeasure or determine force, contact, proximity, or the like.Additionally, or alternatively, such rollers can passively make contactwhile the surface finishing system 100 utilizes its sensors 366, 346,326 (e.g., force and torque sensing) and/or vision systems 364, 324 tomaintain a pressure or force against the datum surface. The informationobtained or determined about tool orientation relative to the portionsof the end effector 160, robotic arm 140 and/or base unit 120 can beused to alter the toolpath, tool parameters and/or other systemconfigurations to ensure the coating automation system can carry out theprocess without running into limitations of the hardware.

In both passive and active embodiments, the angular position of a gimbalor other portion of an end effector 160 can be recorded (e.g., viasensors 366 or vision system 364) to locate and establish the plane ofthe target surface. The angular position of the gimbal can be recordedusing elements including, but not limited to encoders on the rotaryaxis, laser range finders, capacitance sensors, IMUs, an external visionsystem, sonar sensors, potentiometers, motor loads, or any combinationof these.

The gimbal system may be tuned to minimize dynamic effects by usingsprings, dampers or a combination of these. In some embodiments withmore than one blade or roller, all tools may be mounted on a singlegimbal structure or each tool or groups of tools may be mounted onseparate gimbals. Mounting the blades or rollers on separate gimbals canallows for tool surface planes to be set, limited, or controlledseparately. Coating application tools can be mounted on a gimbal inseries with a compliant system described above that limits, sets, orcontrols the force applied on the surface.

In some embodiments, a coating end effector 160M can include elementsincluding, but not limited to a heater, curing light, blower or acombination of these. For example, FIG. 19 illustrates an exampleembodiment 160M8 of a coating end effector 160M that comprises a firstblower 1905 and a second blower 1910. The first blower can be configuredto apply cool and/or dry air to coating 630 that has been applied to thesubstrate 610 by the coating end effector 160M. The second blower 1910can be configured to apply heat and/or dry air to a surface of substrate610 on which coating 630 will be applied. As shown in FIG. 19, thecoating end effector 160M can include a coating applicator 1915 that caninclude a tracking knife 1920 that can be used to profile the coating630. In various embodiments, preheating and drying the surface ofsubstrate 610 on which coating 630 is being applied can improve thecoating application process. Cooling and/or drying the applied coating630 via the first blower 1905 can be desirable to speed thedrying/curing process of the coating 630 and can improve the finish ofthe coating 630.

In various embodiments, elements including but not limited to a heater,fan, UV light, microwave emitter, or a combination of these elements canalso be a separate part of the automated surface finishing system 100.These components can be mounted on an end effector 160, a robotic arm140, mobile base 120, positioning stage 122, gantry, or the like, or canbe static in the room and separate from the automated surface finishingsystem 100. A purpose of these components can be to speed up the curing,drying, or setting time of the coating 630, but can also be used toprepare the surface for the application of tape 640 or coating 630. Anembodiment of the end effector 160 utilizes a heater that leads thecoating application for preheating the substrate surface 610 on whichcoating 630 will be applied by the coating end effector 160M. Thecoating application point can be followed by a blower which can act overthe applied coating 630. The coating end effector 160M can also utilizetwo heaters leading and following the coating application or utilize twofans or a combination of these. The tool parameters or settings on thefan, heaters, or lights may be determined by the planning system (e.g.,by the control system 322) using information from one or more of sensors366, 346, 326 and/or vision systems 364, 324. For example, environmentalsensors (e.g., temperature, humidity, and the like) and a prescribedcoating composition and applied thickness can be used to determine toolparameters for environmental control tools or systems such heaters,coolers, blowers, or the like. In another example, the coating endeffector can comprise a thermal imaging camera to assess the temperatureof the coating 630 and calculate the moisture content of the coating630. The automated surface finishing system 100 can also have a humiditysensor, conductivity sensor and depth or thickness sensors such as laserrange finders, sonar, radar, LIDAR, and the like. Toolpaths, toolparameters settings, coating composition, fan, heater, light settings,and the like can be adjusted in real-time based at least in part on themeasurements, sensing or data obtained from such sensors or visionssystems.

The automated surface finishing system 100 can utilize additives such asplaster of paris to accelerate the setting time of a coating of coating630. An accelerant can be mixed into the coating 630 during preparation,added in at the nozzle 1240, applied to a coating 630 after deposition,or any combination of these. The automated surface finishing system 100can utilize environmental information to decide the amount of accelerantto add and at what point in the process it should be introduced. Inother words data from one or more vision system 324, 364 and/or sensors326, 346, 366 to automatically modify the parameters of the composition,preparation, and application of the coating 630. In some examples,accelerant may be sprayed on to a coating 630 after the coating 630 hasbeen applied onto the target surface.

The automated surface finishing system 100 can utilize sensors (e.g.,humidity or conductivity sensors) that are mounted on a substrate 610before coating application, which can provide for tracking of themoisture content of the substrate 610 and/or coating 630 applied to thesubstrate 610. Such sensors can be mounted directly onto the targetsurface, may be embedded in a joint 620, or can be mounted on a couponthat is covered at the beginning of the process with the sameparameters. Such sensors can be connected to a wireless communicationsystem to send signals/data to the automated surface finishing system100. Moisture content and other information collected by such sensorscan be used to control or adjust the settings on fans, blowers, heaters,curing lights, an HVAC system, or the like. The drying speed can also beused to adjust the composition of the coating 630. Monitoring themoisture content can allow the system 100 to accurately estimate thetime when the next step can begin (e.g., sanding, painting or the like).

The automated surface finishing system 100 can also determine when thecoating has set and dried by measuring the thermal conductivity of thecovered seam 620, using a vision system (such as a thermal imagingcamera); using a sensor such as a thermometer (contact or non-contact),or by detecting differences in colors using a vision system (e.g., dueto color changes that occur between wet and dry coating 630. Variousmeasurements can be used to infer the moisture content of coating 630 bycomparing a determined temperature of the coating 630 to the surroundingmaterials such as the substrate 610. For example, as water or othersolvent evaporates from a mixture of coating 630, the temperature of thecoating 630 can be lower than that of the surrounding materials. Modelsof the coating drying process can also be used to estimate the time todry or cure given a set of starting conditions and information about theenvironment. The environmental sensors and/or vision systems can be usedin conjunction with an HVAC system or heater, air conditioner, fans, orthe like, to control the room conditions at a worksite. The sensorreadings can automatically trigger any of these systems or a combinationto maintain the room at the desired conditions for quality, reduceddrying time, or comfort of the operator.

In various embodiments, the automated surface finishing system 100 canuse one or more vision system 324, 364 and/or sensors 326, 346, 366 toestablish a condition of a wall of the substrate before and aftercompound application to determine appropriate toolpaths and/or toolparameters. The system 100 can use computer vision, structured lights,stereo cameras, images, lights and shadows, LIDAR, radar, sonar, pointclouds or any combination of these to establish the conditions of atarget surface. These conditions can include establishing the surfaceplane relative to a coating application tool or another surface,detecting high or low points, curvature, and defects. One or more of thevision system 324, 364 can be used to create a topographical map of thesurface to identify high and low spots. The map can be created aftersubstrate 610 has been hung. The map can also be an input from asubstrate layout system that specifies the location and types of joints620 and features in the room. The map can be updated by the one or morevision system 324, 364 as the system 100 is moved or moves around theroom. The system 100 can also utilize rollers, proximity sensors,contact sensors, profilometers, and the like, to measure the profile ofthe surface. The robotic arm 140, end effector 160 and/or base unit 120can be used to make contact with rollers or other mechanism on anencoded linear stage and then move these over the surface creating atopographical map. This can be done over joints or seams to determinethe profile. The system 100 can then compute how the coating 630 shouldbe applied and tapered to create a visually flat wall assembly.

To achieve the coating thickness on the substrate 610, the system 100can optimize the delivery of the coating 630 to build up more coating630 on low spots and less on high spots. The system 100 can also useinformation of the joint location to profile the coating delivery toaccount for the height variations typical of joints 620. The endeffector 160 can then be used to apply a specific profile of coating 630to the wall. This can be done by controlling the profile of the sprayer1210, the shape and size of a troweling blade, the distance between theend effector 160 and substrate 610, the flow rate of coating 630, thetool speed, the number of passes over a given spot, or the consistencyof the coating 630. The robotic arm 140 and/or end effector 160 canutilize force control to apply the pressure required to deliver adesired amount of coating 630 or to achieve a desired surface texture orroughness.

A thickness measurement can also be used to determine the amount ofcoating 630 that is to be delivered to a given spot. The system 100 canalso tune the profile of the delivered coating 630 to account foroverlap of the subsequent application. The coating thickness at theedges can be reduced or feathered such that the overlap region achievesthe final desired thickness. This approach can also be used to increaseoverlap error tolerance at transition points between robot workspaces.The automated system 100 can utilize the information about the room,compound mixture and desired compound profile to determine theapplication profile desired to account for shrinkage of the coating 630.The system 100 can also use shrinkage models with environmentalinformation obtained from sensors or vision systems to anticipate theshrinkage of the coating 630 as it dries. The delivered profile canaccount for shrinkage by increasing thickness of coating 630 appliedsuch that the final post-shrinkage profile is the desired profile toachieve a visually flat wall. Compound mixture definition can includereal-time automatic adjustments of gypsum, plaster of paris, and watercontent for optimal results given environmental conditions (determinedbased on data from sensors and/or visions systems), and layer finishrequirements.

The system 100 can be instrumented with vision systems 324, 364 and/orsensors 326, 346, 366 that can be used to improve operation and ensurequality. During compound application the system 100 can use sensors 366(e.g., force and torque sensors) mounted directly on the end effector160, or sensors 346 on the robotic arm 140, and/or force and torqueestimates determined by sensors 346 of robotic joints of the robotic arm140 to apply a desired force during troweling or taping. The visionsystems 324, 364 and/or sensors 326, 346, 366 can monitor force normalto a blade or rollers or on multiple axes including torque measurementsand six-axis sensing. The force sensing can be used to control the forceor pressure applied by one or more tool of an end effector 160. Aminimum force or contact readings can also be used to ensure contact ismade before the coating 630 is allowed to flow, and force below acertain threshold or loss of contact can trigger the stop of jointcompound flow. The automated surface finishing system 100 can use theforce information to operate in force control, where the motions andspeeds of the system 100 are driven to ensure a given force is appliedin the desired directions. Similarly, force sensing can be used todetect contact with an object, obstacle, or intersecting wall orceiling. By monitoring forces and torque on various portions of therobotic arm 140, base unit 120 and/or end effectors 160, the system 100can detect that it has made contact with the adjacent wall or ceilingand alter the toolpath accordingly. The measurements can also be used todetect accidental contact and trigger a safety operation such asstopping the system 100 or retracting away from contact point. Thesystem 100, including the end effector 160 can also use sensors (e.g.,contact or proximity sensors) and/or visions sensors to detect that theend effector 160 is touching the surface, obstacle, object, or worker,as well as detect the distance to an adjacent surface or contact withthat surface. The force, contact, displacement, or proximity sensors canbe mounted on outriggers from the end effector 160 to sense obstacles,objects, or adjacent surfaces ahead of the end effector 160. The system100 can detect, follow, and use adjacent walls as datums to guidecoating application and achieve accurate corners. For example, in someembodiments, the end effector 160 can comprise a guiding elementconfigured to engage a target surface, adjacent walls, or the like, toallow the end effector 160 to be guided in coating the target surface.For example, such a guiding element can include an arm extending fromthe end effector 160, with the arm having a roller at the end of the armconfigured to engage the target surface or portion of a wall assembly asa coating guide.

The base unit 120, robotic arm 140 and/or end effector 160 can utilizemultiple control strategies to complete various tasks. Position controlcan be used to command the system 100 to follow a trajectory givenspeed, acceleration, and jerk constraints. The system 100 can becontrolled at the joint level by giving commands to the joints toachieve the desired robot state and tool position, or the control can bedone at a higher level allowing a user or program to control endeffector position and orientation. The system 100 can be controlled intask space where the system 100 controls a tool relative to the task.This approach can focus on achieving a desired tool position,orientation, speed, or the like, relative to the target surface ratherthan on each joint reaching its target goal. The system 100 can utilizeforce control to control the force applied to the target surface, anobstacle, adjacent surfaces, objects and so on. The applied force can becontrolled in a single or multiple axes. Hybrid control modes can alsobe used. For example the system 100 can be commanded to achieve a givenposition as long as a given force is not exceeded.

The one or both of the vision system 324, 364 can be used to capturewhere and how the coating 630 has been applied. By monitoring the spraypattern applied on the wall the system 100 can detect clogs, nozzle orblade wear, or other problems. In one example, a thermal camera can beused to detect the applied coating 630, which can be at a differenttemperature than the target material. The compound's temperature can becontrolled to facilitate detection. Monitoring the compound temperaturecan also give information on the moisture content of the coating 630.The coating 630 can have a prescribed coloring or additives to createcontrast between the target surface and the coating 630 facilitating thedetection of areas that have been covered by the coating 630. The colorcan change as the coating 630 dries as well as after it has been sanded.The system 100 can also apply coatings 630 in layers with differentcolors in different layers of coating 630 to facilitate detecting howmuch coating 630 has been removed during application or sanding ofcoating 630. Sensing such as capacitance, radar, resistance, humidity,conductivity, sonar measurements, or any combination of these can alsobe used to establish the thickness of the coating 630. Lights can bemounted on the system 100 or externally to illuminate the surfaceenabling the detection of coated surfaces, high and low points, toolmarks, coating roughness, orange peel, and defects using one or both ofvision systems 324, 364.

The system 100 can monitor the coverage achieved by the end effector 160and update tool paths and tool parameters to ensure the desired coatingprofile is being applied. For example, the system 100 can dynamicallytune a sprayer fan and/or bell until the spray pattern matches thedesired shape, thickness, size. The system 100 can also move the sprayer1210 closer or farther away from the target surface to change the spraypattern. The system 100 can also tune the material flow rate, pressure,spray tool speed, or the like, to achieve a desired thickness. Thetoolpaths and/or tool parameters can also be updated to ensure that thecorrect overlap is being achieved.

The system 100 can also utilize a feedback mechanism for communicatingcontact, forces, gimbal displacement information, tool orientation,motor loads, humidity and temperature readings, measurements of theapplied coating 630, to system 100 (e.g., to the control system 322) forthe purpose of real time updating of the tool paths and tool parametersfor improving finish of coating 630. The system 100 can use toolposition and orientation, captured surface conditions and models toupdate the robotic toolpaths to ensure that a desired position and/orcontact is maintained during application of coating 630.

The system 100 can also determine areas that need another application ofcoating 630, rework using automated surface finishing system 100, orrework to be done manually by the user. The user can also use a userinterface of the system 100 to indicate areas that the user hasidentified as needing rework or need to be coated again. The system 100can use this input along with other information about the previous workto create a new toolpath. Both user and system feedback can be fed intoa machine learning algorithm to create a better model for coating futuresurfaces given a set of initial conditions.

The automated surface finishing system 100 can utilize a user interfaceto enable the worker to control, program, debug, plan, and setup thesystem 100. The user interface can be used to give the user informationof all the steps that must be taken to setup the system 100. Each stepcan be checked off when complete and the user can request moreinformation on each step. The workspace of the system 100 can be shownoverlaid on a camera feed or projected onto the target surface to helpthe user position the end effector 160, robotic arm 140 and/or mobilebase unit 120. The workspace can be projected using lights or lasers.The system 100 can also automatically perform certain steps and the userinterface can report the progress of each step, as well as give guidanceto the steps the user can follow to perform a task. The user interfacecan be used to setup the system 100 and run any calibration routinesrequired. The interface can also be used to plan a job includingdetecting wall, user definition of path parameters or path itself, autogeneration of the tool path, user input of tool parameters, andautomatically optimized tool parameters given a set of user inputs.

The user interface can be a graphical user interface and include a 2D or3D representation of the worksite and workspace. The representation caninclude camera feeds as well as computer models and reconstructionscreated using sensor data. The interface can overlay paths, qualityvisuals, progress, robot model, or the like, over camera or workspacemodels. As the task is completed the path can be highlighted indifferent colors or with different style lines to indicate completion,quality achieved, problem areas among others.

Any problems, issues, or bugs can be reported in the user interface.Lights on the end effector 160, mobile base 120 and/or robotic arm 140as well as sounds can also be used to indicate problems, movement of theend effector 160, base unit 120 and/or robotic arm 140; that work is inprogress; that the system 100 is on or off; that toolpath is running orpaused, that the system 100 needs attention or refill of materials; andany other indicators of the system state. The user interface can alsodisplay information on the progress, task and tool parameters, andquality metrics of the task being performed. Environmental conditionscan also be displayed and recorded by the interface. The system 100 canindicate to the user what steps to take to correct or improve conditionsincluding air quality, temperature and humidity. If the system 100detects unsuitable or unsafe conditions it can display a message warningthe user and providing guidance on next steps. The system 100 can use anoptimization to find what parameters could be used to improve theprocess including reducing work time, increasing quality, and minimizingmaterial usage among others. The user interface can also create reportson the tasks executed, quality metrics, environmental conditions,completion, and performance logs. Information can include robotworkspace, tool paths, progress, sequence of approach, application ratesand thicknesses, spray pressures and flow rates, forces applied by thetool, coverage record, path speed, tracking error, time to complete thetask, tool time, setup time, vacuum waste material collected, cleaningtime. The user interface can also display on filter conditions, and thesystem 100 can trigger an alarm or instruction when the filter needs tobe replaced or cleaned.

The user can interface with the system 100 using a computer, tablet,touch screen, mobile device, pendant, joystick, controller, or buttonsdirectly on the system 100. The worker can also position and train therobotic arm 140 and/or end effector 160 by directly moving joints of therobotic arm 140 or end effector 160. The user interface, controller, orbuttons can be used to record positions as well as change the controlmode and task.

An augmented reality system can be used to show the worker a toolpathplan generated by the system 100, instructions, original BIM or plan, ora combination of these. The augmented reality can be displayed using aheadset, smart goggles, projections, or the like. The worker can beshown areas that require manual coating application. The user can alsooverlay the location of studs, framing, pipes, ducts, electrical systembehind the board to facilitate compound application. Coating tools, bothmanual and automated can be tracked in the map using tags, IMUs, orother sensors and a warning can be given to the operator if an attemptis made to apply coating 630 in an erroneous position or under the wrongtool settings. The system 100 or tools can also utilize radar, sonar,thermal imaging to establish what is behind the substrate.

The automated surface finishing system 100 can also produce avisualization, paths, or instructions or a combination of these to guidethe user in completing manual work. The visualization can include 2D or3D maps marking the areas of work with labels. The visualization systemcan also include a projection of the plan onto the target surface thiscan be done with a laser system, projector or through augmented realityheadset or goggles worn by the user.

The coating time, pressure, material flow rate, coating characteristics,and clogs can be tracked to inform when a nozzle 1210 or blade 1130should be cleaned or changed. For example, FIG. 20 illustrates anexample embodiment 160M9 of a coating end effector 160M, which comprisesa nozzle cassette system 2005 where a cassette of nozzles 1240 isattached to the end of the spray gun 1210. The cassette system 2005 canbe rotated (e.g., via an electromechanical system) to deliver a nozzle1240 to the spray gun 1210 for use.

FIG. 21 illustrates another example embodiment 160M10 of a coating endeffector 160M that comprises of a nozzle rotating system 2105 that canbe part of a spray gun 1210. In this example, the system 100 can utilizean actuator assembly 2110 (e.g., a servo or other electromechanicalactuator) to rotate (e.g., 180 degrees) a portion 2115 of the nozzle1210 allowing for coating 630 to go through the nozzle portion 2115 inreverse helping clear out clogs.

In various embodiments, nozzle or blade wear models can also take as aninput the type and characteristics of coating 630 applied and theconditions under which such coating 630 was applied. One or more visionsystem 364, 324 of the system 100 can be used to detect finish, toolpattern and establish if the nozzle 1240 or blade 1130 needs to bechanged, rotated, cleaned or otherwise modified. A user interface candisplay the wear on the nozzle 1240 or blade 1130 and alert the userwhen these need to be changed. A coating end effector 160M can alsoinclude a mechanism to automatically replace or clean the nozzle 1240 orportions thereof. One embodiment (e.g., FIG. 20) can use a cassette withreplacement nozzles 1240 that can be rotated into place. The sprayer1210 can also have a mechanism 2105 to rotate the nozzle or portionthereof (e.g. a tip or feeding tube) to clear a clog (e.g., FIG. 21).The nozzle clearing or replacement can be run automatically by thesystem 100 without any human intervention or as a collaboration betweenthe system 100 and the user.

The system 100 can generate reports and interface with other softwareplatforms including BIM packages. Reports can be created that can beused for inspection and certification. A report can be customized toprovide the information required to pass a standard, test, orcertification. The reporting system can also provide a live update ofthe current task progress and live camera feed. This information can beused to help track asset performance and work progression. The data canbe reported to a BIM system or other software to facilitate planning ofother trades, next steps, or schedule inspections or other tasks. Thereports can include full maps of the coating 630 applied and tool andpath parameters utilized to complete the task. Further images or videocan be recorded to facilitate quality checks or for tracking of issues.The system 100 can record parameters used to complete the task which canbe fed to a machine learning software to enable the system 100 to learnfrom past work. The reports can also be used to optimize workflow andscheduling. The system's optimization function can be updated to meetthe desired needs including minimizing task time, completion of the taskin a part of the worksite to allow other trades to come in, minimizingcost, optimal use of assets and workforce, among others. The system'sreports can also include information on environmental conditions and howthe process was changed given the conditions.

The system 100 can create a report that shows the process parametersthat were used to cover the surface as well as the order of operations.The report can include BIM, 3D and 2D maps or plans, images, video. Themaps provided by the system 100 can be used to facilitate repairs andmaintenance by providing the customer with the location of componentsbehind the wall as well as the location of seams to facilitate theremoval of panels or boards.

The updated room models that reflect the as built conditions andmeasurements can be exported for use in sanding the walls or forcertification of quality at delivery. A complete map of the thickness ofthe compound applied with or without shrinking can be fed into thesystem 100 or a separate automated sanding system which can plan toolpaths and parameters desired to achieve the desired finish by sanding.The system 100 can work in conjunction with a larger system that plansthe full process from mapping a room, to cutting and hanging thesubstrate to finishing and painting of the surfaces. The system 100 canbe used for coating surfaces with any suitable material, including butnot limited to one or more coating 630, which can include jointcompound, plaster, gypsum, concrete, stucco, cement, paint, polymercoating, lacquers, varnishes, or any combination of these. The coating630 can also comprise polymers such as latex, acrylics, or the like,and/or adhesion additives including glue and other bonding agents. Thecoating 630 can comprise a synthetic material such as Parex, an acrylicsynthetic stucco, or the like. The system 100 can apply the coating(s)on any suitable substrate, including but not limited to drywall, boards,lath, mesh, or other substrates. The system 100 can also be used toapply other coatings such as wallpaper, polymer films, or the like.

The system may also utilize an end effector mounted on the robotic armto layout and attach the substrate to the structural components. FIG. 22illustrates an example embodiment of a substrate applicator end effector160R, wherein a roll of substrate 610 is mounted within a roll body 2220of the end effector 160 and fed under a roller 2230. The substrate endeffector 160R can be moved over a target surface and the roller 2230 topush the substrate 610 into place in-between or over the studs 830 of awall assembly 800 or other suitable location. For example, substrate 610can be applied vertically or horizontally between studs 830 orhorizontally or vertically over studs (e.g., as shown in FIGS. 8b, 9aand 9b ). In various examples, the substrate end effector 160R can usestuds 830 or other suitable framing element or other feature as a datumfor guiding the insulation end effector 160I.

In some embodiments, the width of substrate 610 can be set to match aspacing width between studs 830, height of the wall, or the like. Forexample, a substrate end effector 160R can comprise a blade, laser orother cutter that can be used to cut substrate 610 to size before,during or after application of the substrate 610. Additionally, adhesivecan couple substrate 610 within a wall assembly 800 or other suitablelocation. For example a roll of substrate 610 can be pre-impregnatedwith adhesive before or during application; a substrate end effector160R can apply adhesive ahead of the substrate 610 to help secure thesubstrate 610 to a stud 830, or the like.

In some examples, an adhesive can be applied with an end effector 160 byspraying. Some examples can include a separate end effector 160 havingan adhesive spray gun, or an adhesive spray gun can be part of asubstrate end effector 160R, that is configured to apply adhesive infront of the substrate 610 onto a surface that the substrate 610 isbeing applied to and/or by applying the adhesive onto the substrate 610before the roller 2230.

FIG. 23 illustrates an example embodiment of an automated wall finishingsystem 100 where a substrate end effector 160 utilizes studs 830 of awall assembly 800 as a guide for delivering substrate 650 between or onthe studs 830, header 810 and footer 820 of the wall assembly 800. Asshown in FIG. 23, the end effector 160 can comprise an arm 2310 having aroller 2320 that can be pressed against an internal face of a stud 830for guiding the sprayer 1210. In various examples, the substrate endeffector 160 can utilize the surrounding surfaces as datums and aroller, wheel, blade, or the like, and can be pushed in contact withsuch a datum surface or feature for reference.

Such contact points can extend away from a substrate application zone toenable the use of datums away from the where the sprayer 1210 isapplying the coating 630. For example, FIG. 23 illustrates the endeffector 160 having an arm 2310, which can allow the sprayer 1210 to bespaced centrally between the studs 830, while the roller 2310 contactsone of the studs 830 for use as a datum.

In various embodiments, the end effector 160 can control the position ofthe contact points such that the correct or optimal datum surface isused. For example, the arm 2310 can be extendible and retractable toprovide for a desired offset from the stud 830 or other contact surface.Additionally, the force and pressure on contact points can also becontrolled. For example, force can be directly or indirectly measured orestimated by monitoring the deflection of the mounting structure, andthe like. In one embodiment, the spray end effector 160 can utilize aroller 2310 to guide the sprayer 1210 along a stud 830 or other portionof a wall assembly as shown in FIG. 23. In some examples, the system 100can operate in hybrid force and position control following the stud 830and spraying the coating 630 in a target area relative to the stud 830.

In various embodiments, the system 100 can include a cutting tool fortrimming the substrate 610 and/or coating 630 after the substrate 610and/or coating 630 has been applied. For example, the system 100 cancreate a map or model of a room given a set of substrate applicationparameters and/or by directly mapping the room after the substrate 610and/or coating 630 has been applied. A model or map of the room withsubstrate 610 and/or coating 630 can be used to determine areas thatneed to be trimmed or cut to enable the closing of the walls andinstallation of doors, windows and the like. In some examples, asubstrate cutting tool can follow a front edge of studs 830, or othersuitable framing element, and cut substrate material 610 and/or coating630 that protrudes beyond the plane of the stud 830. In one embodiment,a substrate/coating cutting system can comprise a blade that is pushedalong the edge of a stud 830, which can remove substrate 610 and/orcoating 630 that extends beyond the face of the stud 830. Thesubstrate/coating cutting tool can be powered or unpowered in variousembodiments. The robotic arm 140 and/or end effector 160 can be used todrive a substrate cutting tool through the substrate 610 and/or coating630. Additionally, substrate 610 and/or coating 630 can be cut to createroom for electrical boxes, wires, framing, conduit, pipes, or any othermechanical, electrical or plumbing component.

The one or more vision systems 364, 324, sensors 624, 644, 664, and/ormodel of the room or structure may be used to determine the amount ofsubstrate 610 and/or coating material 630 to adequately cover the targetsurfaces (e.g., over or between studs 830, over substrate 610 coupled toa wall assembly 800, or the like). In various embodiments, suchestimates can be used to pre-order materials (e.g., substrate 610,coating 630, and the like) and estimate duration of the job. Theenvironmental conditions of the site can be monitored to determinecuring and drying times and estimate the duration of the task or timeremaining in a task. The site temperature, humidity, light, airflow, andthe like can be controlled to affect drying, setting, and/or curingtimes of substrate 610 and/or coating 630. De-humidifiers, heaters,fans, blowers, coolers, humidifiers, lights, or a combination of thesecan be mounted on the system 100 or the room to control theenvironmental conditions.

The coating material 630 (e.g., depending on the first coat, second coatand third coat, where present) can have different performance propertiesthat allow for different finish textures to be achieved. The coatingmaterial 630 can be sprayed using an airless or air driven system. Thecoating material 630 can also have different performance propertiesbased on code compliance pertaining to sound isolation, fire retardancy,weight distribution, and hardness of materials that can allowbuilding-specific design intents to be accomplished. The deliverymechanism for coating 630 can include texture sprayers, paint sprayers,concrete sprayers, purpose built sprayers, and the like. The mixedcoating 630 can be pumped directly to a nozzle 1240 or can be mixed intothe liquid at or beyond the nozzle 1240. The nozzle 1240 may utilizecartridges or a feeding tube to deliver powder, slurry, or additives(e.g., as shown in FIG. 14). The cartridge or mixing nozzle may bedisposable. The coating mixture 630 can be controlled to achieve adesired material property including viscosity, water content, mixturecomposition, and the like. The material composition can also becontrolled depending on the monitored environmental conditions. Thedesired substrate material, geometry, orientation (vertical, horizontal,angled), schedule, and target finish can be used to determine theoptimal coating mixture.

A nozzle 1240 or pump may be instrumented with a sensor to control acoating material delivery rate. Such a sensor can monitor pressure, flowrate, mass rate, trigger position, and the like. A nozzle orificeopening can be controlled to set the coating material delivery rate, thecoating particle speed, the coating mixture composition, coatingtexture, and the like. The nozzle orifice can be controlled to producethe desired coating material delivery including coating spray shape,size, and the like. The size of the orifice can be controlled using amotor, servo, valve, or the like. The size of the orifice can be changedby changing the distance between two cones in some examples.

The system 100 can use a variety of nozzle shapes and sizes to deliverthe coating, including fan and bell shapes. The tool may include anozzle carousel (e.g., as shown in FIG. 20) that the operator or system100 can use to change the tip on the sprayer. The coating material 630can be deposited evenly over the substrate 610, which can ensure thesurface of the substrate 610 is covered with a consistent thicknesswhich can certify fire, insulation or sound ratings.

In some embodiments, a vacuum system can be used to control overspray(e.g., as shown in FIG. 16). For example, a vacuum inlet can be mountednext to the nozzle and can utilize a hood that follows or surround thenozzle to capture the overspray. The vacuum system may also be mountedon the mobile base. In further embodiments, an air stream can be used tocontrol coating overspray, to direct the coating spray or to control thesize and/or shape of the coating spray.

For example, FIG. 24 illustrates an example embodiment 160M11 of acoating end effector 160M having a spray gun 1610 that comprises acoating nozzle 1640 surrounded by one or more air nozzles 2440. As shownin the example of FIG. 24, the one or more air nozzles 2440 can generatean air flow curtain 2430 about the coating spray 700, which can controloverspray of the coating spray 700, direct the coating spray 700,control the size and/or shape of the coating spray 700, or the like. Forexample, the one or more air nozzles 2440 can selectively focus ormodify the coating spray 700 as necessary to generate a desired effect.

An air flow curtain 2430 can be generated in various suitable ways byone or more air nozzles 2440. For example, in some embodiments, aplurality of separate air nozzles 2440 can be disposed surrounding thecoating nozzle 1640. In another embodiment, a ring nozzle can define anair nozzle 2440 that surrounds the coating nozzle 1640. The one or moreair nozzles 2440 can be fed via various suitable sources including froma compressed air source located at the base unit 120 or other suitablelocation about or apart from the system 100. Also, in furtherembodiments, any suitable fluid can be used to generate the flow curtain2430.

The system 100 can include a cleaning or clearing system and process toclear a coating nozzle 1640 of clogs. Such a cleaning or clearing systemcan be used to clear or flush the entire system from pump to nozzle ofmaterial in some examples. The system 100 can automatically detect(e.g., through pressure sensors or time) when the spray system should becleared and in response can automatically run a cleaning routine for thespray system. The cleaning routine can also be triggered by the operatorat the end of the cleaning process or when problems arise. The portionsof the system 100 associated with storing and generating a spray ofcoating 630 can be designed to be sealed to the environment so that nocuring or drying of the coating 630 happens within the system 100 (e.g.,the compound source 430, compound lines 432, a pump, or the like).

The described embodiments are susceptible to various modifications andalternative forms, and specific examples thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the described embodiments are not to belimited to the particular forms or methods disclosed, but to thecontrary, the present disclosure is to cover all modifications,equivalents, and alternatives.

What is claimed is:
 1. A method of generating a wall or ceiling assemblyusing mobile robotic coating system, the method comprising: constructinga first assembly comprising an elongated linear header and an elongatedlinear footer with a plurality of elongated linear studs extendingbetween the elongated linear header and the elongated linear footer, thefirst assembly defining a planar first assembly face defined byrespective faces of the elongated linear header, the elongated linearfooter, and the plurality of studs; generating, by a computationalplanner, a model of the first assembly based at least in part on one orboth of data obtained by a vision system of the mobile robotic coatingsystem and a building plan uploaded to the computational planner, themodel including a mapping of a location of one or more openings and/orone features of the first assembly; determining, based at least in parton the generated model of the first assembly, a plan for the mobilerobotic coating system spraying a coating material onto specifiedlocations of a plurality of pieces of flexible multi-layer substratedisposed on the planar first assembly face, the plan based at least inpart on the location of the one or more openings and/or the features ofthe first assembly; and spraying, based at least in part on thedetermined plan, the coating material onto the plurality of pieces offlexible multi-layer substrate disposed on the planar first assemblyface, the plurality of pieces of flexible multi-layer substrateincluding a first base layer that is coupled to the plurality of studsand is at least impermeable to the coating material, and a flexiblesecond porous or mesh layer having voids where the coating material canenter and adhere, the spraying comprising: the mobile robotic coatingsystem spraying the coating material onto the plurality of pieces offlexible multi-layer substrate via a coating end effector, the coatingend effector comprising a sprayer configured to apply the coatingmaterial to a target surface via a nozzle coupled with a mobile storagecontainer storing the coating material, the coating materialimpregnating the voids of the second porous or mesh layer withoutpermeating through the first base layer that is coupled to the pluralityof studs, and allowing the coating material impregnating the voids ofthe second porous or mesh layer to dry and harden and become rigid togenerate the wall or ceiling assembly.
 2. The method of claim 1, furthercomprising: applying the plurality of pieces of flexible multi-layersubstrate to the planar first assembly face with the mobile roboticcoating system, the applying including: the mobile robotic coatingsystem rolling the plurality of pieces of flexible multi-layer substrateover at least the plurality of studs, and the mobile robotic coatingsystem coupling the plurality of pieces of flexible multi-layersubstrate to the plurality of studs via a substrate end effector, thesubstrate end effector comprising: a roll of the flexible multi-layersubstrate mounted within a roll body of the substrate end effector; anda substrate roll cutter configured to cut the roll of the flexiblemulti-layer substrate to generate the plurality of pieces of flexiblemulti-layer substrate.
 3. The method of claim 2, wherein the mobilerobotic coating system further comprises a computing device executing acomputational planner that: generates instructions for driving themobile robotic coating system to perform at least: a substrate taskincluding the applying the plurality of pieces of flexible multi-layersubstrate to the planar first assembly face, and a coating taskincluding the spraying the coating material onto the plurality of piecesof flexible multi-layer substrate disposed on the planar first assemblyface drives the mobile robotic coating system to perform the substratetask and coating task, and updates toolpaths associated with thesubstrate task and the coating task in real time based on data obtainedfrom a vision system of the mobile robotic coating system.
 4. The methodof claim 2, further comprising: trimming the plurality of pieces offlexible multi-layer substrate disposed on the planar first assemblyface based on a location of at least one of door location and a windowlocation in the first assembly, and wherein generating the plurality ofpieces of flexible multi-layer substrate is based at least in part on amap or model of the first assembly including a configuration of theelongated linear header, the elongated linear footer, and the pluralityof studs.
 5. The method of claim 1, wherein mobile robotic coatingsystem tunes characteristics of the coating material sprayed onto theplurality of pieces of flexible multi-layer substrate based on desiredfinish characteristics of the wall or ceiling assembly.
 6. The method ofclaim 1, wherein the spraying end effector further comprises a mixingnozzle coupled with a mobile storage container storing coating materialand wherein spraying the coating material onto the plurality of piecesof flexible multi-layer substrate disposed on the planar first assemblyface further comprises: the sprayer applying coating material onto theplurality of pieces of flexible multi-layer substrate via the mixingnozzle, the mixing nozzle mixing coating material received from themobile storage container with at least one of an accelerant, fibers, atinting material, and pigmenting material at the mixing nozzle, theaccelerant accelerating setting time of applied coating materialcompared to setting time of applied coating material without theaccelerant.
 7. The method of claim 1 further comprising generating adesired coating material finish of coating material sprayed onto theplurality of pieces of flexible multi-layer substrate disposed on theplanar first assembly face by one or more of: dragging a blade over thecoating material sprayed onto the plurality of pieces of flexiblemulti-layer substrate, while the coating material is wet, the bladebeing part of and controlled by the coating end effector; and sandingcoating material sprayed onto the plurality of pieces of flexiblemulti-layer substrate after the coating material has dried, the sandingperformed by a sanding end effector of the mobile robotic coatingsystem.
 8. A method of generating a building assembly, the methodcomprising: generating a model of a plurality of pieces of substratedisposed on a first assembly face based at least in part on one or bothof data obtained by a vision system and a building plan; determining,based at least in part on the generated model, a plan for spraying acoating material onto the plurality of pieces of substrate disposed onthe first assembly face; and spraying the coating material onto theplurality of pieces of substrate disposed on the first assembly face,the spraying comprising: spraying the coating material onto theplurality of pieces of substrate via a sprayer configured to apply thecoating material to a target surface via a nozzle coupled with a mobilestorage container storing the coating material, the coating materialimpregnating voids of the substrate, and allowing the coating materialimpregnating the voids to dry and harden and become rigid to generatethe building assembly.
 9. The method of claim 8, wherein spraying thecoating material onto the plurality of pieces of substrate disposed onthe first assembly face includes a mobile robotic coating systemspraying the coating material onto the plurality of pieces of substratevia a coating end effector, the coating end effector comprising thesprayer configured to apply the coating material to the target surfacevia the nozzle coupled with the mobile storage container storing thecoating material.
 10. The method of claim 9, further comprising applyinga plurality of pieces of the substrate to a first assembly face with asubstrate end effector of the mobile robotic coating system, theapplying including the mobile robotic coating system rolling theplurality of pieces of substrate over at least the first assembly face,and wherein a roll of the substrate is mounted within a roll body of thesubstrate end effector.
 11. The method of claim 10, further comprising:the mobile robotic coating system coupling the plurality of pieces ofsubstrate to the first assembly face via the substrate end effector; andthe mobile robotic coating system cutting the roll of the substrate togenerate the plurality of pieces of substrate, the substrate endeffector comprising a substrate roll cutter that cuts the roll of thesubstrate to generate the plurality of pieces of substrate.
 12. Themethod of claim 11, further comprising trimming the plurality of piecesof substrate disposed on the first assembly face based on a location ofat least one of door location and a window location in the firstassembly, and generating the plurality of pieces of substrate is basedat least in part on a map or model of a first assembly that defines thefirst assembly.
 13. The method of claim 9, wherein the mobile roboticcoating system further comprises a computing device executing acomputational planner that: generates instructions for driving themobile robotic coating system to perform at least a coating taskincluding the spraying the coating material onto the plurality of piecesof substrate disposed on the first assembly face; drives the mobilerobotic coating system to perform the coating task; and updatestoolpaths associated with the coating task in real time based on dataobtained from a vision system of the mobile robotic coating system. 14.The method of claim 9, wherein the mobile robotic coating system tunescharacteristics of the coating material sprayed onto the plurality ofpieces of substrate based on a desired finish characteristic of thebuilding assembly.
 15. The method of claim 8, wherein the sprayerfurther comprises a mixing nozzle coupled with the mobile storagecontainer storing coating material.
 16. The method of claim 15, whereinspraying the coating material onto the plurality of pieces of substratedisposed on the first assembly face further comprises: the sprayerapplying coating material onto the plurality of pieces of substrate viathe mixing nozzle, the mixing nozzle mixing coating material receivedfrom the mobile storage container with at least one of an accelerant,fibers, a tinting material, and pigmenting material at the mixingnozzle, the accelerant accelerating setting time of applied coatingmaterial compared to setting time of applied coating material withoutthe accelerant.
 17. The method of claim 8 further comprising generatinga desired coating material finish of coating material sprayed onto theplurality of pieces of substrate disposed on the first assembly face bydragging a blade over the coating material sprayed onto the plurality ofpieces of substrate, the blade being part of and controlled by at leastone of the coating end effector and a finishing end effector coupled toand controlled by the mobile robotic coating system.
 18. The method ofclaim 8 further comprising generating a desired coating material finishof coating material sprayed onto the plurality of pieces of substratedisposed on the first assembly face by sanding coating material sprayedonto the plurality of pieces of substrate, the sanding performed by asanding end effector of the mobile robotic coating system.
 19. Themethod of claim 8, wherein the substrate of the plurality of pieces ofsubstrate comprises a flexible multi-layer substrate including: aflexible first base layer that is at least impermeable to the coatingmaterial, and a flexible second layer having voids where the coatingmaterial can enter and adhere.
 20. The method of claim 8 furthercomprising constructing a first assembly comprising an elongated linearheader and an elongated linear footer with a plurality of elongatedlinear studs extending between the elongated linear header and theelongated linear footer, the first assembly defining the planar firstassembly face defined by respective faces of the elongated linearheader, the elongated linear footer, and the plurality of studs.